You are here: Acknowledgments

Acknowledgments
CFER Technologies (1999) Inc. ("CFER") gratefully acknowledges the
cooperation, technical input, and financial assistance received from the
participating companies (the "Participants") under the Joint Industry Project
entitled Progressing Cavity Pumping (PCP) System Technology Development.
Without the Participants' valuable contributions the development of PCPUMP
would not have been possible.

You are here: Licence Agreement

PC-PUMP
Software Licence Agreement
This legal document is an Agreement between you, the end user (the "User")
and C-FER Technologies (1999) Inc. ("C-FER"). By clicking the applicable
button to complete the installation process and/or opening or running the PCPUMP application executable file, the User is agreeing to be bound by the
terms of this Agreement. If the terms and conditions of this Agreement are
unacceptable, the User shall click the appropriate button to cancel the
installation process, not install or use the Software, and return the Software
with all accompanying materials and containers to C-FER and the User will be
entitled to a refund of the Licence Fees paid, if applicable.
DEFINITIONS:
"Bug" means any reported, documented and reproducible error, defect, or
problem with the Software, as reproduced by C-FER using its own equipment,
with the Users' assistance upon C-FER's request.
"Demo Version" means a version of the Software issued to the User by CFER with a limited number of calculation runs and period of use, for the
purposes of evaluation only.
"Hardlock" means either a Stand Alone Hardlock or a Network Hardlock, as
defined herein.
"HASP" means either a Stand Alone HASP or a Network HASP, as defined
herein.
"Help File" means the electronic documentation contained within the
Software which describes the specifications of the Software including its
general use, functions, capabilities and operation.
"Licence Fees" means the amount payable to C-FER by the User as
consideration for the right to use one or more copies of the Software.
"Maintenance Fee" means the applicable fee payable by the User to C-FER
for the Services provided during a Maintenance Period as amended from time
to time.
"Maintenance Period" means, as applicable, the initial period commencing

as of the Shipping Date and ending on December 31 of the same calendar year
(Initial Maintenance Period), and thereafter each subsequent period of twelve
(12) consecutive months.
"Network Hardlock" means a hardware device attached to a network server
with one or more Network Seats used in conjunction with the Software as a
copy protection measure.
"Network HASP" means a hardware device attached to a network server
with one or more Network Seats used in conjunction with the Software as a
copy protection measure.
"Network Seat" means a single licence provided to the User through a
Network Hardlock or Network HASP.
"Packet" means a sealed packet containing one or more Hardlocks or HASPs
and a digital storage medium which contains the Software.
"Regular Support Hours" means the hours between 8 a.m. and 5 p.m.
(Mountain Standard Time or Mountain Daylight Time, as applicable) on the
regular business days of C-FER.
"Shipping Date" means the Software date of shipment as recorded by C-FER.
"Software" means the computer software known as PC-PUMP.
"Stand Alone Hardlock" means a hardware device attached to a computer
used in conjunction with the Software as a copy protection measure.
"Stand Alone HASP" means a hardware device attached to a computer used
in conjunction with the Software as a copy protection measure.
"Supporting Materials" means all items accompanying the Software (on a
digital storage medium) including the Hardlock or HASP and this Agreement.
"Upgrades" means any Bug fixes, technical features, capabilities, or
enhancements included in a new version of the Software.
"Vendor Databases" means databases contained within the Software
describing specifications of standard and vendor specific equipment used to
design, construct and operate progressing cavity pumping systems as used in
the production of downhole fluids common to the oil and gas industry.
"User" means collectively: any individual who clicks the applicable button to
complete the installation process, any individual who opens or runs the PC-

PUMP application executable file, the company which purchased PC-PUMP from
C-FER and the company which owns or possesses the PC-PUMP licence(s).
"WEBLock Service" means a connection the User has to a licence held on CFER's server used in conjunction with the Software as a copy protection
measure.
1.0 Licence
C-FER grants to the User a non exclusive, non transferable right to install and
use the Software subject to the terms and conditions set forth in this
Agreement.
2.0 Ownership
C-FER retains all property, rights, title and interest in and to the Software and
any Upgrades, including, without limitation, all trademarks, trade names,
copyrights, patents and other intellectual property rights. The User shall not
copy the Software (subject to Section 4.0) or the other written materials
accompanying the Software, nor shall the User modify, adapt, reverse
engineer, decompile, disassemble or convert the Software into human readable
form or direct a third party to do the same.
3.0 General Use of Software
The User shall use the enclosed Software on only one computer at any given
time for each licence purchased. Use on a computer is deemed to occur when
the Software (or a part of it) is loaded in temporary memory (i.e. RAM) and
communicates with a Stand Alone Hardlock attached to the same computer,
with a Network Hardlock over an internal network, or with C-FER's WEBLock
Service.
4.0 Permitted Software Copying
The User may make a copy of the Software for backup or archival purposes.
5.0 Restricted Use of Software
The User shall not rent, lend, lease or transfer the Software to any third party
without C-FER's consent, which consent will not be unreasonably withheld. The
User shall not use the Demo Version in any instructional manner where the
instructor is being compensated for their knowledge of the Software.
6.0 Maintenance and Software Support

C-FER shall provide the following maintenance and software support services
to the User at no cost for the Initial Maintenance Period, or as otherwise
provided in writing by C-FER at the time of sale:
(a) Software Support.
C-FER shall provide to the User the following software support:
(i) Reasonable telephone support during Regular Support Hours and advice
relating to the use of the Software, its installation and potential software or
hardware technical problems resulting from perceived incompatibilities
between the Software and specific User software or hardware
configurations; and
(ii) Prompt investigation and reply to the User in response to any user
detected Bug.
The software support described in this section 6(a) is not to be used for
educational or software training purposes and shall specifically exclude
engineering consulting services.
(b) Maintenance.
C-FER shall use reasonable efforts to correct Bugs in the Software when
such Bugs are reported to C-FER. All reports of suspected Bugs shall be
communicated to C-FER by telephone or e-mail and shall provide details
sufficient to diagnose or reproduce such Bugs, including a description of the
circumstances in which the suspected Bug occurred. Under no circumstances
does C-FER represent or warrant that all Bugs can or will be corrected.
C-FER shall provide User with any Bug fixes, if such Bug is correctable, if
and when they are developed by C-FER and made generally available to
other licencees of the Software.
(c) Upgrades.
C-FER shall provide to the User having paid the Maintenance Fees for the
appropriate Maintenance Period any releases of new versions of the
Software that include optional technical features, capabilities, or
enhancements that extend beyond those specifications described in the User
Guide. Upgrades shall be provided by C-FER to the User by digital storage
medium or by the User downloading the new version of the Software from
the Software website and shall include a Software Licence Agreement which
shall replace and supersede the Software Licence Agreement for the
previous version of the Software.

(d) Vendor Database Updates.

C-FER shall use reasonable efforts to ensure that the Vendor Databases are
kept current.
Maintenance and Software Support, as described in this section will be
provided to the User beyond the Initial Maintenance Period upon payment of
Maintenance Fees by the User to C-FER. Failure of the User to pay an
invoice for Maintenance Fees issued by C-FER to the User at or near the
start of each Maintenance Period after the Initial Maintenance Period will
result in the suspension of all Maintenance and Software Support to the
User by C-FER. Maintenance and Software Support, as described in this
section does not apply to Users of Demo Versions of the Software.
7.0 Vendor Databases
C-FER gives no warranty and makes no representation that:
(a) any equipment vendor will continue to participate by providing data and
specifications relating to their products to C-FER;
(b) any data or specifications relating to any vendors not yet incorporated
within the Software will be added to the Vendor Database; or
(d) any information contained within the Vendor Database, whether provided
by a vendor or obtained by C-FER from public domain sources and, as it
existed at the Shipping Date, or as it may be revised or updated by C-FER from
time to time, is accurate or reliable.
8.0 Virus Protection
C-FER warrants that the Software and any Bug fixes shall be free of any
viruses as detected by anti virus software used by C-FER in its sole discretion
from time to time as of the Shipping Date. Other than the aforementioned
warranty, C-FER does not warrant that the Software and any Bug fixes shall be
totally virus-free.
9.0 Limited Warranty and Disclaimer
(a) C-FER warrants that it has full power and authority to grant the rights
granted herein without the consent of any other person.
(b) C-FER warrants that the Software will perform the functions and operate in
the manner described in the Help File for the duration of the Maintenance
Period.

(c) THE WARRANTIES CONTAINED IN SUBSECTIONS (a) AND (b) HEREOF ARE
IN LIEU OF ALL OTHER WARRANTIES OR CONDITIONS, EXPRESS OR IMPLIED,
INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OR CONDITIONS
OR MERCHANTABILITY, MERCHANTABLE QUALITY, FITNESS FOR A PARTICULAR
PURPOSE, AND INFRINGEMENT AND THOSE ARISING BY STATUTE OR
OTHERWISE IN LAW OR FROM THE COURSE OF DEALING OR USAGE OF
TRADE. C-FER DOES NOT REPRESENT OR WARRANT THAT THE SOFTWARE
WILL MEET ANY OR ALL OF THE CUSTOMER'S PARTICULAR REQUIREMENTS,
THAT THE SOFTWARE WILL OPERATE ERROR FREE OR UNINTERRUPTED AND
THAT ALL PROGRAMMING ERRORS IN THE SOFTWARE CAN BE FOUND IN
ORDER TO BE CORRECTED.
10.0 Infringement Indemnity
(a) C-FER shall indemnify and hold User harmless from any and all claims,
damages, actions and costs (including legal costs on a solicitor-client basis)
brought against the User by a third party which may arise out of or are in any
way related to infringement or conflicts with any rights of such third party
related to the Software delivered by C-FER to User in accordance with the
terms of this Agreement. C-FER will pay all costs and damages awarded by a
court of competent jurisdiction as a result of any such third party claims;
provided that User promptly (i) notifies C-FER in writing of such claim; (ii)
gives C-FER complete authority for the defence of any claim of infringement;
and (iii) gives assistance and full cooperation for the defence of any such
claim.
(b) The foregoing indemnity will not apply to any claim based upon or arising
from (i) use of the Software in a manner for which it was not intended; or (ii)
use of the Software when use of a subsequent software release made
commercially available would have avoided any such infringement; or (iii)
User's continued use of the Software subsequent to receipt of notice of any
claimed infringement.
(c) If the Software in C-FER's opinion, is likely to or does become the subject
of a claim for infringement, C-FER, at its option, shall either modify it to
become non-infringing, or C-FER may terminate this Agreement. If C-FER
elects to terminate this Agreement in accordance with the foregoing sentence
and termination occurs less than a year after purchase of the Software, C-FER
will pay User an amount equal to the Licence Fees less 10% of such Licence
Fees for each calendar month elapsed from the Shipping Date to the date of
termination of this Agreement. If termination of this Agreement occurs more
than a year after the Software was purchased, C-FER will pay User an amount
equivalent to the Maintenance Fees pro-rated for the number of months
remaining in the current Maintenance Period. THE FOREGOING STATES THE

ENTIRE LIABILITY OF C-FER WITH RESPECT TO CLAIMS FOR INFRINGEMENT.

(d) Neither party shall be liable to the other party for any consequential,
incidental or indirect losses or damages, including, without limitation, loss of
revenue, loss of income or loss of anticipated profits, which result from or are
in anyway attributable to this Agreement.
11.0 User Remedies
C-FER's entire liability to the User, and the User's exclusive remedy, shall be,
at C-FER's sole discretion, either: (a) repair or replacement of the Software,
Help File or Hardlock that does not meet C-FER's Limited Warranty (Section
9.0); or (b) termination of this Agreement and refund to the User of Licence
Fees paid by the User when a Bug prohibits the User from using the Software
during the Limited Warranty period (Section 9.0) or during any period when
the User has purchased maintenance and support services (Section 6.0). If CFER elects to terminate this Agreement in accordance with the foregoing
sentence and termination occurs less than a year after purchase of the
Software, C-FER will pay User an amount equal to the Licence Fees less 10%
of such Licence Fees for each calendar month elapsed from the Shipping Date
to the date of termination of this Agreement. If termination of this Agreement
occurs more than a year after the Software was purchased, C-FER will pay
User an amount equivalent to the Maintenance Fees pro-rated for the number
of months remaining in the current Maintenance Period. The Limited Warranty
(Section 9.0) is void if failure of the Software or Supporting Materials has
resulted from accident, abuse or misapplication by the User, and any remedy
corresponding to such failures will be subject to costs as established by C-FER.
Any replacement of the Software or Hardlock will be warranted for the
remainder of the original Maintenance Period or thirty (30) days, whichever is
longer. Under no circumstances shall C-FER be liable for a breach of the
Limited Warranty set out in Section 9.0 if the User attempts to alter or modify
the Software in any way, without first obtaining express written approval from
C-FER. Users reporting a lost or stolen Hardlock to C-FER shall receive a
replacement Hardlock subject to a replacement fee.
12.0 Liability
In no event shall C-FER be liable for any other damages whatsoever
(including, without limitation, damages for loss of business profits, business
interruption, loss of business information, or other pecuniary loss) arising out
of the use of the Software, even if C-FER has been advised of the possibility of
such damages. Except for the warranties provided in Section 9.0, the entire
risk as to the results and performance of the Software is assumed by the User.
The User agrees to hold C-FER harmless from any loss, damage or claim

resulting from its use of the Software in violation of this Agreement. Except for
claims relating to third party intellectual property infringement (Section 10.0
and 11.0), C-FER's entire liability under any provision of this Agreement shall
be limited to the amount of the Licence Fees for the Software paid to C-FER by
the User.
13.0 Termination
This Agreement is in effect from the time the Software is installed until the
Agreement is terminated. The User can terminate this Agreement at any time.
C-FER may terminate this Agreement upon giving notice to the User if the
User has failed to comply with any term or condition contained within this
Agreement. Termination of this Agreement shall occur on the day such notice
is received by the User.
Upon termination of this Agreement by either the User or C-FER, the User
shall: (a) destroy all copies of the Software on the original digital storage
medium; (b) destroy all subsequent copies of the Software held on separate
digital storage media for back up or archival purposes; and (c) purge all copies
held on the hard drive of computers controlled by the User. Within thirty (30)
days following the termination of this Agreement and the subsequent
destruction and removal of the Software by the User, the User shall provide CFER with a notice certifying that to the best of the User's knowledge, all copies
of the Software held by the User have been destroyed. In the event that C-FER
terminates this Agreement, the User shall, within three (3) working days of
receiving C-FER's termination notice, return all Supporting Materials to C-FER.
14.0 Controlling Law
This Agreement shall be constructed, interpreted and governed by the laws in
force in the Province of Alberta, Canada. The parties hereby submit to the
jurisdiction of the Courts of Alberta.
15.0 Notices
All notices required or permitted hereunder shall be in writing and shall be
personally delivered or sent by registered mail or transmitted by facsimile as
follows:
C-FER:
PC-PUMP Technical Support Group
C-FER Technologies (1999)
pcpump@cfertech.com

Inc.

Telephone:

(780)

450-3300

mail:

200 Karl Clark Road Facsimile: (780) 450-3700 Websites: www.cfertech.com,

www.pc-pump.com
Edmonton, Alberta
CANADA T6N 1H2
USER: registered contact will be the address provided by User on the official
PC-PUMP order form or to such other address or fax number as either party
may designate by written notice delivered to the other party hereto. Any
notice delivered personally or sent by facsimile shall be deemed to be received
when left or faxed during normal business hours at the office set forth above,
and any notice sent by prepaid registered mail shall be deemed to have been
received on the fifth (5th) normal delivery day following posting.
The PC-PUMP Home Page (http://www.pc-pump.com) may provide access to
PC-PUMP general information, technical bulletins, frequently asked questions,
Bugs, Bug fixes, and Upgrade notices.
PC-PUMP Software Copyright 2014, by C-FER Technologies (1999) Inc. All
rights reserved.
PC-PUMP is a Registered Trademark of C-FER Technologies (1999) Inc.

You are here: Copyright

Copyright
CFER retains the copyright to the PCPUMP software and the PCPUMP Help File.
The copying of PCPUMP on any medium, except as specifically allowed under
the terms and conditions of the Licence Agreement, is strictly prohibited. No
portion of the PCPUMP Help File, in whole or in part, including text, figures,
tables, graphic illustrations, etc. can be reproduced or transmitted in any form
or by any means, electronic or mechanical, including photocopying and digital
recording, without the express written permission of CFER. Such permission
shall not be unreasonably withheld and shall be subject to providing an
acknowledgment of CFER with a full and complete reference to the source
document.
PCPUMP Software Copyright , by CFER Technologies (1999) Inc. All rights
reserved.
PCPUMP Help File Copyright , by CFER Technologies (1999) Inc. All rights
reserved. Printed in Canada.
PCPUMP is a registered trademark of CFER Technologies (1999) Inc. in
Canada and the United States of America.
CFER and the CFER logo are trademarks of CFER Technologies (1999) Inc.
IBM is a registered trademark of International Business Machines Corporation.
Microsoft and Windows are registered trademarks of Microsoft Corporation.
Hardlock and HASP are registered trademarks of Aladdin Knowledge
Systems Ltd.
Adobe and
Incorporated.

Acrobat

are

registered

trademarks

of

Adobe

Systems

You are here: Disclaimer

Disclaimer
The "PCPUMP software" and the "PCPUMP Help File" are hereinafter collectively
referred to as the "PCPUMP Package".
End-users of the PCPUMP Package are cautioned to undertake appropriate
assessments for fitness of purpose and verification of results as the
PCPUMPPackage is provided "AS IS" and CFER specifically disclaims any
warranty that the functions contained within PCPUMP shall meet end-user
requirements or in a manner selected for use by the end-user. CFER provides
the PCPUMP Package to end-users on the basis that PCPUMP shall perform
substantially in accordance with the PCPUMP Help File and the end-user
acknowledges by its use of the PCPUMP Package , that PCPUMP and the PCPUMP
Help File, in general, are not error free and agree that the existence of such
errors shall not constitute a breach of the Licence Agreement.
Information within the PCPUMP Help File is subject to change without notice
and does not represent a commitment on the part of CFER. CFER, at its sole
discretion, may produce, from time to time, modifications and/or updates of
PCPUMP and/or the PCPUMP Help File. Such modifications and/or updates may
be made available to end-users by CFER and may require the payment of an
updating fee. CFER does not warrant that any future updates of the PCPUMP
Package will be error free or that all previously identified defects will be
corrected.
The Help File, at times, may provide information to help end-users of CFER's
PCPUMP software select equipment for a given application. Designing an
application is an iterative process; some equipment is selected, the expected
operating conditions are entered, the results are analyzed, and then the
design improved upon according to criteria defined by the end-user.
Also, while portions of the Help File cover issues relating to basic PC pump
system design, they may not cover all nuances related to more complicated
designs. For more detailed assistance, please contact CFER Technologies at
780-450-3300 or by email at pcpump@cfertech.com.
Portions of the Help File were prepared based on methodology of design by
CFER Technologies (1999) Inc. ("CFER") for end-users of PCPUMP and
participants of the PCP System Design and Performance Optimization Courses
("Users"). All reasonable efforts were made to ensure that the information
contained in the Help File conforms to accepted scientific, engineering and
environmental practices, but CFER makes no other representation and gives
no other warranty with respect to the reliability, accuracy, validity or fitness of

the information, analysis and conclusions contained in the Help File. CFER
warrants that the work prepared by CFER was done in a competent, thorough
and diligent manner, with the care, skill and diligence reasonably to be
expected of firms similar to CFER, of ordinary competence measured by
professional standards prevailing at the time the work was performed. Any
and all implied or statutory warranties of merchantability or fitness for any
purpose are expressly excluded. Any use or interpretation of the information,
analysis or conclusions contained in the Help File is at the User's own risk.
Reference herein to any specified commercial product, process or service by
trade name, trademark, manufacturer or otherwise does not constitute or
imply an endorsement or recommendation by CFER.

You are here: Customer Support

Technical Support
CFER offers technical support for PCPUMP questions and business-related
matters, such as:

information about software support and maintenance plans;

upgrade information or ordering an upgrade;
problems with software packages (items missing or defective); and
general product information.

CFER can be contacted using the following methods:

Feedback/Support Form: Click on the email icon to launch a Feedback form
that enables you to quickly email PC-PUMP Technical Support with any
issues or suggestions you may have. The email icon is located on the
navigation bar or can be accessed through the Help option in the main
menu.
Phone: 1-780-450-3300
Note: PCPUMP technical support is available Monday through Friday
9:00 am to 5:00 pm (Mountain Time).
Email: pcpump@cfertech.com
Website: www.pc-pump.com/contact

For technical matters, please first consult the PCPUMP Help File contained in
the software, which constitutes a comprehensive reference for all aspects of
the software. The Help File included in the software can be accessed at any
time by pressing the F1 key or using the Help menu option. As well, Help icons
are located strategically throughout the software to provide targeted
information on the area of the software you are working in.

The PCPUMP home page, www.pc-pump.com, also provides access to PCPUMP

technical bulletins, a frequently asked question list, bug fixes and upgrade
notices. New program releases and database updates can be downloaded
directly from this site.
If a question remains after consulting the Help File and the PCPUMP website,
please contact Technical Support using any of the methods listed above.

You are here: PCP Systems Overview

PCP Systems Overview

In the late 1920's, Rene Moineau developed the concept for a series of helical
gear pumps1,2. One of these pumps took the form of what is now known as
the progressing cavity pump (PCP), screw pump or Moineau pump. Since
1930, PCPs have been used extensively as fluid transfer pumps in a wide
range of applications from industrial and manufacturing environments to the
surface transfer of oilfield fluids. However, with the exception of several
limited field trials, it was not until the early 1980's that a concerted effort was
made to utilize PCPs as a method of artificial lift for the petroleum industry3.
Over the last ten years, PCP systems have experienced a gradual emergence
as a common form of artificial lift. As of 1998, it was estimated that there
were approximately 30,000 wells worldwide operating with these systems.
Presently the major applications for PCP systems include:
heavy oil and bitumen production with sand cuts of up to 50%;
medium crude oil production with limits on H2S production;
light sweet oil production with limits on aromatic content;
dewatering of coalbed methane wells;
mature waterfloods;
source water wells;
mature steam drive operations; and
visual or height sensitive areas.
PCPs are positive displacement pumps which typically consist of a helical steel
rotor and a synthetic elastomer stator bonded inside a steel tube. Rotation of
the rotor within the fixed stator causes a series of sealed cavities to form and
move axially from the pump suction to the discharge. The resulting pumping
action moves fluid through the pump from the lower intake pressure to the
higher discharge pressure so that it can be produced to surface. Several
papers5,6,7 which describe PCP principles and theory are listed in Appendix A:
References.
Most PCP systems are rod-driven with the stator run into the well on the
bottom of the production tubing, and the rotor run into the well on the bottom
of the rod string. To turn the rotor downhole, the rod string is rotated at
surface by means of a hydraulic or direct drive power transmission. A typical
rod-driven system is illustrated in the figure below. More recently, downholedriven PCP systems have become available. These rod-less systems use a

downhole motor and gearbox assembly to drive the rotor.

Configuration of a Typical Surface Drive PCP System

Configuration of a Typical Downhole Drive PCP System

PCP systems possess unique characteristics which can make them preferable
over other artificial lift systems. Their most important characteristic is high
overall system efficiency. PCP systems typically exhibit overall efficiencies of
60 to 70%, which is higher than any of the other major artificial lift types.
Some additional advantages of PCP systems include:
the ability to produce high viscosity fluids, large solids concentrations and
moderate percentages of free gas;
no rod fall issues;
low internal shear rates which limit fluid emulsification by agitation;
no valves or reciprocating parts to clog, gas lock or wear;
low capital and power costs;
relatively simple installation and operation as well as low maintenance;
and
low profile and low noise surface equipment.
An additional advantage of PCP systems is their inherent ability to function
effectively in a wide range of operating environments. The applications in
which they are currently employed include variations in:
well profiles: vertical, deviated, slant and horizontal;
fluid viscosity: 1 to 100,000 cp;
fluid composition: low to high sand and water cuts as well as low to
moderate gas/oil ratios;
fluid rates: 1 to 1500 m3/day (6 to 9000 bbls/day); and
temperature: 10C to 180C (50F to 350F).
PCP systems also have some disadvantages compared to other forms of
artificial lift. The most prominent of these are limitations with respect to pump
capacity, lift and elastomer compatibility with produced fluids. The list below
summarizes the current application limitations and major operational
difficulties associated with PCP systems:

limited production rates: maximum = 1500 m3/day (9000 bbls/day);

limited lift: maximum = 4000 m (13000 ft);
limited temperature capability: maximum = 180C (350F);
sensitivity to fluid environment - elastomer may swell or deteriorate when
exposed to certain fluids;
tendency for the pump stator to sustain permanent damage if pumped dry
even for short periods; and
lack of experience with system design, installation and operation.
These limitations are rapidly being overcome with the development of new
products and improvements in materials and equipment design. In the correct
application, PCP systems provide the most economic (and in some cases the
only) means of artificial lift if configured and operated properly.
For additional information on PCP systems, please consult the references listed
in Appendix A: References.

You are here: PCP Design and Optimization

PCP Design and Optimization

One of the primary advantages of progressing cavity pump (PCP) systems is
their inherent ability to function effectively in a wide range of operating
environments. However, successful operation of PCP systems requires the use
of systems with different configurations.
Collectively, the numerous
equipment selection and well completion options available, variations in
operating conditions, and complex fluid flow and mechanical interactions can
make the assessment and design of PCP systems both difficult and time
consuming.
Design optimization through manual calculations is usually impractical and,
when done repeatedly, inefficient because of the excessive time required to
perform multiple parametric analyses. PCPUMP can be used to perform a wide
range of assessments related to PCP system design and operation. To use
PCPUMP effectively, you must know what information you need and how to
enter it in order to get the results you require.
In preparing to use PCPUMP, you should first ask yourself the following
questions:
What input data and constraints do I have?
What am I trying to determine/evaluate?
To what degree do I need to optimize the system performance?
An analysis with PCPUMP consists of the following steps:
1. inputting the wellbore geometry in the Wellbore Geometry window;
2. selecting the pump, rod, tubulars, and surface or downhole drive
equipment in the Equipment Configuration window;
3. specifying the fluid properties and operating conditions in their respective
windows;
4. running an analysis using the Case Manager and Options window;
5. examining the results in the Analysis Results window; and
6. iterating through the above steps to optimize the system design by
changing the entered equipment and conditions.
Note that many of the input sections are optional for completing a basic PCP
system assessment. Consult the Analysis Results section of the Help File for
detailed information on what inputs are required for each results output
window.

You are here: Installing PC-PUMP > System Requirements

System Requirements
To run PCPUMP successfully your system must have, as a minimum, the
following features:

Hardware
256 megabyte (MB) RAM or higher
hard drive with at least 250 megabytes of free space (additional space
should be available after installation to save your working files);
display adapter and monitor supported by Microsoft Windows at a
resolution of at least 1024 X 768 pixels; and
CD-ROM drive or internet access (preferred) for software installation.

Software
Windows XP, Windows Vista, or Windows 7, Windows 8, Windows 2008
Server, or Windows 2012 Server.
Note: As a Windows-based program, PCPUMP supports and uses the device
drivers provided by Microsoft as well as others specifically designed for use
with Windows. PCPUMP does not provide drivers for ancillary equipment
such as printers, plotters, display adapters, pointing devices etc.

You are here: Installing PC-PUMP > Installation

Installation
This section describes a typical installation. Please see the documentation that
was sent with your PCPUMP package for more information.
User files containing custom equipment, wellbore geometry, sample sessions
and pump tests are located in a folder under:
"Documents and Settings\username\PC-PUMP3" folder for Windows XP;
and
"Users\username\PC-PUMP3\User" folder for Windows 7.
To ensure that user files and preferences are available, they are automatically
imported from older versions during the installation sequence.
PCPUMP is located in the "CFER Technologies\PC-Pump" folder for v3.x and
newer. Older versions of PCPUMP are located in the "PCPUMP Version 2.6"
folder in the "Program Files" folder. The installation of PCPUMP v3.x will
remove any links to older versions of PCPUMP v3.x that exist in the Windows
Start Menu. Any shortcuts on the desktop should be updated to point to the
new PCPUMP software location in the program files directory.
PCPUMP is shipped on CD; however, it is recommended to download the latest
version from the PCPUMP website.
You can install the software on an
individual computer or in a network environment.
To install PCPUMP on your personal computer:
1. Make sure that no other major applications are running on Microsoft
Windows.
Note: To ensure that the installation program completes successfully,
please log in with administrator privileges.
2. If you are installing from a CD, insert the PCPUMP CD into your CD-ROM
drive. Copy the installation program from the CD to your desktop. Once it
has been copied, double-click on the icon to start the installation process.
Alternatively, if you are installing from a downloaded installation program,
simply double-click on the icon for that program after downloading it. The
installation progress will begin.

Click

Next

and the installation will proceed.

3. You will next be asked to accept the PCPUMP Licence Agreement before
continuing with the installation:

Read the Licence Agreement (a paper copy is shipped with every copy of
PCPUMP and is also located in the Help File). You can also print a copy of
the Licence Agreement by clicking the Print button. If you agree to the
terms of the licence, check the I accept the terms box and click on Next.
4. Confirm the installation location:

Click on

Next

to proceed.

5. Once these settings have been made, the program is ready to be installed:

Click Install to proceed with the installation.

following message will appear:

When it is complete, the

6. Your PCPUMP installation is now complete.

Click Finish to exit the
installation program. You can also select to Launch PCPUMP upon exiting the
installation program.
7. If you do not already have the Adobe Acrobat Reader installed, you may
wish to install it when the PCPUMP installation is complete. A free copy of
Acrobat
Reader
is
available
from
Adobe's
website
at
http://www.adobe.com.

Related Topics

System Requirements
Network Hardlock Installation
Network HASP Installation
Licence Protection
Updating Hardlock Feature Codes
Using PCPUMP

You are here: Installing PC-PUMP > Network Considerations

Network Hardlock Installation

If you are using a network Hardlock, you will need to install the Hardlock
server software on a computer so that it can act as the network Hardlock
server. This can be installed on the same computer where you use PCPUMP.
However, in a production environment it is recommended to place this on a
machine that is always running such as a network server.

Server Installation Instructions

Microsoft Windows Based Hardlock Server
Please note that you will need Administrator access privileges to perform the
following installation.
1. Download the Hardlock server program from the following url:
ftp://ftp.aladdin.com/pub/aladdin.de/hardlock/hlsw32_inst.zip,
unzip it and run the installation program hlsw32.exe from the hlsw32_inst
directory.
2. Download the Aladdin monitor program from the following url:
ftp://ftp.aladdin.com/pub/aladdin.de/hardlock/aksmon.zip,
unzip it and run the installation program aksmon32_setup.exe from the
aksmon directory.
3. Run the Aladdin monitor program. It should be in the start menu under:
Start Menu->All Programs->Aladdin->Monitor->AKS Monitor
From the monitor program perform the following steps to install the
PCPUMP module.

1. Locate the server in the HL-Server list on the left.

2. Click on it to select it.
3. Enter the module address 17092 and click the Add button. You will
need to have the network key plugged in to the network Hardlock

server for this to work.

4. You should see the module appear in the list (see screenshot).

Other Hardlock Server Environments

The network Hardlock server can also reside on a Novell or Linux server. If
you would like more information on using the Hardlock server on these
operating systems, please contact CFER at (780)450-3300 or at
pcpump@cfertech.com.

Client Installation Instructions

1. Install PCPUMP on the client computer by following the instructions
obtained from CFER. Part of the installation process is installation of the
Hardlock Drivers. This must be done whether a network or stand-alone
Hardlock is to be used. You must have Administrator access privileges to
do this.
2. If the network Hardlock is on a different sub-net on your network from the
computer you are using to run PCPUMP, PCPUMP may not be able to locate
the Hardlock without special instructions. In order to run PCPUMP with a
network key in this case, you must enter the following environment
variables into your operating system. Contact your computer support
personnel for assistance with this.
SET HL_SEARCH=IP
SET HLS_IPADDR=<ip address of server>
SET HLS_WAIT=5000

If your company has more than one network Hardlock for PCPUMP, you can
enter the IP addresses of multiple servers, separated by commas. PCPUMP
will attempt to use them in order (i.e. it will try the server listed first, and
move on to subsequent servers only if the first one is unavailable).
If you have any questions about PCPUMP, the upgrade, or how to install it,
please contact CFER at (780)450-3300 or at pcpump@cfertech.com.

Troubleshooting
The network setup for PCPUMP is a little more difficult that the traditional
stand-alone installation because of the network communications involved.
Here are a few things to try if you cannot get PCPUMP to run correctly.
1. Ensure that the Hardlock is connected to the computer running the
Hardlock server software.
2. Ensure that there is no firewall software blocking the communications
between the PCPUMP program and the Hardlock server. This can be quickly
checked by disabling the firewall software and trying PCPUMP. It may be
necessary to create the appropriate firewall rules to allow this
communication. PCPUMP communicates using UDP port 3047.
3. Install the Aladdin monitor software on the client computer and run it. You
should see the Hardlock server in the list. If you do not then check the
environment settings described in the client installation section of this
document. Although not normally necessary on a local network, it can be
helpful to enter these environment settings on the workstation to assist it
in finding the network server.
4. If you are using a USB network key you can check to make sure that the
server detects it using the computer management application in Windows.
Right-click on the Computer icon and select manage. Go to the device
manager and select it. Expand the Universal Serial Bus Controllers section
and look for the Hardlock device.

Note: The hardware Hardlock that was provided with the software must be
present on each local workstation that attempts to run PCPUMP.

Related Topics
System Requirements
Licence Protection
Updating Hardlock Feature
Codes

Installation
Using PCPUMP

You are here: Installing PC-PUMP > Copy Protection

Licence Protection
PCPUMP licences are copy-protected through the use of a hardware-based copy
protection system. This system uses a device known as a "Hardlock" or
"HASP" that is attached to a USB port. In this document, references to a
Hardlock also apply to a HASP, where the HASP is an alternate version of the
Hardlock. One Hardlock is issued with each licensed copy of the software.
Periodic checks for the presence of this Hardlock are made by the program
during its execution. This measure prevents unlicensed use of PCPUMP.
The Hardlock enables the operation of PCPUMP on any computer to which it is
attached. The software may reside on as many computers as you require;
however, the Hardlock must be present in order to run the program.

Standard Hardlock
The standard Hardlock is included with each PCPUMP software package. It
attaches to the USB port on your computer. If you have an older parallel port
Hardlock and wish to exchange it for a USB Hardlock, please contact PCPUMP
Technical Support for more information.
To install the Hardlock:
1. Locate a USB port on your computer.
2. Connect the Hardlock to this port.
3. If the program is properly installed and the Hardlock has been activated by
CFER, you will now be able to run PCPUMP.

Parallel Port Hardlock

If requested, CFER can supply a parallel port Hardlock which plugs into a
standard parallel port.

Network Hardlock
A network version of the PCPUMP Hardlock is available. A network Hardlock is
installed on a server machine and a Hardlock server program is then
executed. Once the Hardlock server is running, any other computer that can
access the Hardlock server over the network can run PCPUMP without the need
for a local Hardlock. The server will administer licensing and allow up to the
set maximum number of licensed copies of PCPUMP to be simultaneously
executed. This type of protection is suitable for larger installations that would

like to monitor the number of simultaneous users of PCPUMP from a central

location.
To obtain a network Hardlock or answers to any questions regarding the
implementation of a network Hardlock, please contact P C P U M P Technical
Support.

Related Topics
Updating Hardlock
Feature Codes
Automatic Upgrade
Checking

You are here: Installing PC-PUMP > Updating Hardlock Feature Codes

Updating Hardlock Feature Codes

PCPUMP uses the programmability of the security Hardlock provided with the
software to control software licences and maintenance subscriptions. Users
who choose to upgrade their software will be able to do so without having to
obtain a replacement Hardlock from CFER.
To add a new feature to an existing Hardlock, you must first contact PCPUMP
Technical Support at CFER to obtain Hardlock programming information for
the features you wish to add. As new features and updates are released, users
who are eligible to receive them will receive written notification of the
updates.
Upon contacting Technical Support to add a new feature, you will be asked for
your Hardlock serial number. Each program feature is assigned a numerical
code. CFER will provide you with this code as well as an alphanumeric code
that will serve as a verification "key" to program your Hardlock with the
selected feature. Keep a record of the feature code and the verification key
code.
Follow these steps to program your security Hardlock with a new feature:
1. Make sure your Hardlock is attached to the USB port (or parallel port for
older versions) on your computer.
2. Launch the program. If the current Hardlock licence allows the software to
run, then go the Help menu option and select "Add/Upgrade Features". The
window shown below will appear, listing all currently active features on the
Hardlock including its serial number. If the Hardlock licence does not allow
the software to run, a window will appear indicating so. Click on the
"Add/Upgrade" button to access the window shown below.

3. Type the Feature to Add and the Verification Code provided to you by
CFER. Click Add/Upgrade to activate the feature. The window will
automatically update to show the new list of active features for the
Hardlock.
4. If you wish to add other features, repeat step 3 as many times as
necessary. When you are finished adding features, click Close to return to

the main program window. You will now be able to run the updated version
of PCPUMP with the modified Hardlock.

Note that once you have done this, the upgraded information is stored in the
Hardlock itself, and you will not need to repeat this on any other computers
you may use that Hardlock on. (You will, however, have to upgrade the
program on those computers.)
To view the information about the Hardlock, select "About..." from in the
menu.

Help

Please direct any inquiries with respect to adding new features to the PCPUMP
Technical Support team at CFER (see the Technical Support section at the
beginning of this Help File).

Related Topics
Licence Protection
Automatic Upgrade
Checking

You are here: Installing PC-PUMP > Automatic Upgrade Checking

Automatic Upgrade Checking

Many users of PCPUMP are not using the most recent version to which they are
entitled through membership of their company in the PCPUMP Maintenance
Plan. One reason for this may be that all our notices to users are issued only
to the official contact for each company, and not to each user individually. It is
impossible for CFER to keep a complete list of users, as Hardlocks/HASPs may
be passed around within each company without CFER's knowledge.
CFER recommends that all users use the most recent available version of
PCPUMP to which they are eligible. For this reason, PCPUMP can check through
an internet connection to see if newer versions are available.
CFER understands that some companies may not allow programs such as
PCPUMP to access the internet automatically. In such cases, this feature can
be turned off. This feature is enabled by clicking the Edit menu option and
selecting "Preferences". Then, under the Default Switches tab, checking the
Check for program updates on startup box.
Even if the user does not enable the feature, he/she may still manually
instruct PCPUMP to perform a check for available upgrades, through the
PCPUMP Help menu option. After performing a manual check, the window that
appears will give the user the option of turning automatic checks on again by
checking the Continue to check for updates box.

It is possible for a company's IT administrator to remove this capability in such

a way that users cannot turn it back on or perform manual checks. Any IT
administrator wishing to remove this capability should contact CFER for more
information. Users with access to the internet can always check the PCPUMP
webpage (http://www.pc-pump.com/pc-pump-software/current-version) for
information on the latest version of PCPUMP.
No information from a user's computer is transmitted to CFER in this process.
CFER maintains a web page which can be read by PCPUMP. The only thing
transmitted by PCPUMP is a request to read that pageno different than what
any browser transmits when a user wishes to visit a website. PCPUMP
internally compares the version number stored on that website with its own
version to determine if a new version is available. PCPUMP will also check a
value on that website to determine if the user's Hardlock/HASP has been
activated to run the available version. If a new version is available, but the
user's Hardlock/HASP has not been activated, a message to that effect will

appear on the screen. The user can then either contact CFER or the official
contact at the user's company to obtain activation codes. Users must know
their Hardlock/HASP serial number when contacting CFER for activation codes.
When a new upgrade for PCPUMP is available and the Check for program updates on
startup option is checked in the Preferences window, a New Update Available! button
on the toolbar will be visible upon restart of the software. Clicking on this
button will allow the user to download the new upgrade.

When a new version is available on checking, a window similar to the following

will appear:

The user has these options:

1. Clicking Skip This Update tells PCPUMP not to display this window again
(unless a manual check is performed) until the next version is released.
2. Clicking OK will close PCPUMP, since it cannot be upgraded while running,
and open the PCPUMP upgrades web page using the default browser. From
there, the user can download the upgrade.

Checking the Continue

checking for upgrades.

to check for updates

check-box controls the automatic

Users are warned that they should obtain the necessary activation codes
before downloading and installing the new version, as they will not be able to
run the new version without the codes.

Related Topics
Licence Protection
Updating Hardlock
Feature Codes

You are here: Getting Started > Using PC-PUMP

Using PCPUMP
If you are new to PCPUMP, then the following step-by-step guide will help you
familiarize yourself both with the structure of the program and how to move
through it.
In PCPUMP, there are two main sections: the inputs section and the results
section. The inputs section allows you to enter your wellbore profile, select
vendor equipment from the PCPUMP database, enter fluid information and
specify operating conditions. Once PCPUMP has finished analysing your system,
the results section allows you to look at key parameters and graphs that
describe the performance of the system.
The following steps are the suggested path through the program; however,
when you become more familiar with PCPUMP you will find that there are
multiple ways of taking advantage of the power of the software.
1. Specify the wellbore geometry in the Wellbore Geometry tab;
Note: PCPUMP assumes a vertical well if no wellbore geometry is entered.
2. Specify the pump seating depth, mid-perforation depth and equipment in
the Equipment Configuration tab;
Equipment lists are generated from PCPUMP's extensive equipment
database and contain all of the specifications necessary for the subsequent
computations.
Note: The user cannot enter or modify the database information.
However, the user may create custom databases for pumps, surface
brakes, and downhole drive equipment.
3.
4.
5.
6.

Specify the fluid properties in the Fluid Properties tab;

Specify the operating conditions in the Operating Conditions tab;
Click the Calculate button to analyse the entered system;
View the results in the Analysis Results tab.

Other major areas of the program include:

Preferences: Window which allows you to customize certain aspects of the
program.

Database Viewer: Window which allows you to view equipment

specifications on all equipment in the database.
Comparison Tables and Charts: Windows which let you directly compare
the results from any multi-run calculation analysis.
Auxiliary Analysis Windows:
Windows that allow you supplementary
analysis.

Related Topics
Wellbore Geometry
Equipment Configuration
Fluid Properties
Operating Conditions
Analysis Results
Setting Program Preferences
Database Viewer
Comparison Table
Comparison Chart

You are here: Getting Started > Setting Program Preferences

Setting Program Preferences

PCPUMP provides you with the flexibility to customize several aspects of the
program. This is done through the Preferences window which you can access
by clicking the Edit menu option and selecting "Preferences". Tabs at the top of
the Preferences window move you between its various sections that are
described below. You have the ability to set program preferences for units,
defaults, correlations and paths. Once you have made any desired changes,
clicking the OK button will return you back to the original window and activate
any changes. Clicking the Cancel button will return you back to the active
window without making any changes to your preferences settings.

Units
The Units tab of the Preferences window allows you to customize the programs
display units. The window shown below lists numerous categories which can
be individually set to either Metric or Oilfield units. Above the headings of the
two groups are buttons which allow you to set all of the categories to either
Metric (SI) or Oilfield units with a single click. Once a selection has been
made, all future screen displays and reports will follow the new convention. In
the top left corner, the Units source drop-down list allows you to select
between your units ("User Units") and units contained in a loaded file ("File
Units"). The user units are selected by default when a new file is created or
an existing file is opened. Only after a file has been opened can you select file
units as the display units. Files created prior to the release of PCPUMP v2.70
do not contain file units and a notice of such will be displayed if the file units
are selected. New files and files created prior to the release of PCPUMP v2.70
will automatically use your units. If the new file units are different then the
existing file units when saving a file, a confirmation window will be displayed.
The confirmation window will allow you to cancel the save action, save the file
and keep the existing file units or save the file and overwrite the existing file
units with the current file units.

Preferences - Units Input Window

To quickly change the units from SI to Oilfield, you can use the Toggle Units
button. This button enables the user to quickly toggle between SI units,
Oilfield units, and their selected default units.

Toggle Units Button

When the Toggle Units button is pressed, the status bar at the bottom left-side of
the window is updated showing which units are currently active.

Toggle Units Status Bar Notice

Default Values
The Default Values tab of the Preferences window allows you to specify default
values for the following program parameters:
Pump Friction Torque (Static): Mechanical frictional torque in the pump.
If a pump test is not specified, this constant value is combined with the
calculated hydraulic torque to determine the total pump torque.
Volumetric Efficiency (Static): The volumetric efficiency of the pump. If a
pump test is not specified, this constant value is used to calculate the fluid
rate from the pump speed or vice versa.
Gas Specific Gravity:
Specific gravity (relative to air at standard
conditions) of the produced gas.
Water Specific Gravity: Specific gravity (relative to water at standard
conditions) of the produced water.
Sand Specific Gravity: Specific gravity (relative to water at standard
conditions) of the produced sand. (This refers to the relative density of a
sand grain, not a quantity of sand grains that has porosity.)
Tubing Roughness: Average absolute wall roughness of the tubing and tail
joints. Used in frictional pressure loss calculations. Note that a value of
0.1829 mm (0.0006 ft.) is recommended for downhole oilfield
applications46.
Free Gas Separation (intake above perforations): Percentage of free gas at
either the pump, tail joint, or shroud intake that is separated and diverted
up the casing/tubing annulus. Used in multiphase flow calculations to
determine the annular and tubing gas rates. For natural separation, a
value of 30-60% is recommended45. This value is used when the pump,
tail joint, or shroud intake is above the perforations.
Free Gas Separation (intake below perforations): Similar to the value
above, except that this value is used when the pump, tail joint, or shroud
intake is below the perforations. The default value here when PCPUMP is
installed is 100% - this means that any free gas at the perforations is

assumed to go up the casing. In some cases (e.g. if the clearance between

the tubing and casing is small, causing high flow velocities which can "pull"
gas down, or if there is high viscosity) a value less than 100% may be
appropriate.
Power Supply Frequency: Frequency of input supply power. Typically 50
or 60 Hz. Used in electric motor calculations.
Power Supply Voltage: Line-to-line voltage of input power. Used in
surface prime mover calculations.
Power Cost: Unit power cost. Used in daily energy cost calculations.
Gas Specific Heat: Specific heat of produced free gas. Used in heat
transfer calculations for multiphase flow.
Kelly Bushing Offset: The vertical distance between the drilling rig's Kelly
Bushing and the wellhead.
Bottomhole Temperature: The temperature at the mid-perforation depth.
For most of these parameters, the default value only represents an initial
value and changes can be made to the parameter within other program
windows. However, for the gas specific heat and tubing roughness parameters,
the Preferences window is the only place where they can be set.
Changes made to the default values and switches become active once you exit
the Preferences dialog using the OK button. However, changes in the values
will not be reflected in any of the PCPUMP output until after you have
recalculated the results.
During original program installation, the defaults are set to:
Pump Friction Torque (Static): = 108 Nm (80 ftlbs)
Volumetric Efficiency (Static)= 100%
Gas Specific Gravity = 0.70
Water Specific Gravity = 1.00
Sand Specific Gravity = 2.65
Tubing Roughness = 0.1829 mm (0.0006 ft.)
Free Gas Separation (intake above perforations) = 40%
Free Gas Separation (intake below perforations) = 100%
Power Supply Frequency = 60 Hz
Power Supply Voltage = 460 V
Power Cost = 0.050 $/kWh
Gas Specific Heat = 1.85 kJ/kgK
Kelly Bushing Offset = 0 m

Bottomhole Temperature = 0C (enter alternate value in F)

Preferences - Default Values Input Window

For most of these parameters, the default value only represents an initial
value and changes can be made to the parameter within other program
windows.
Changes made to the default values become active once you exit the
Preferences dialog using the OK button. However, changes in the values will
not be reflected in any of the PCPUMP output until after you have recalculated
the results.

Default Switches
The Default Switches tab of the Preferences window allows you to specify
default values for the following program parameters:
Use user path for default file save/load path:

This is normally turned off. When it

is turned off, the file Open and file Save/Save As windows will always
default to the directory which was last used to open or save a file. When it
is turned on, these dialogs will always default to the path specified in the
Paths tab of the Preferences window.
Display output messages after calculation: This controls the feature whereby the
Analysis Calculation Messages appear in a separate window which must be
clicked on to acknowledge the messages after each calculation. If you do
not like this feature, you can turn it off here. If it is turned off, these
messages are still available for viewing in the Output Messages area in the
Summary tab of the Analysis Results window, and you should always read
them, whether or not you decide to turn this feature off.
Check for program updates on startup: This is used to enable or disable checking
for upgrades during software startup.
Autosave using interval: This is used to control the frequency of autosave
backups of the current file. If the check-box is unchecked, then the
autosave feature will be disabled. After checking the box, use the up and
down buttons to select the desired interval in minutes.
Vertical projection at angle of last survey point: This control is normally turned off.
When it is turned off, the vertical section is calculated along a plane that
extends from the latitude and departure of the last survey point to the
origin of the wellbore survey. This method of calculating the vertical

section is consistent with how the vertical section is commonly

calculated.When it is turned off, the vertical section is calculated along a
plane parallel to the azimuth of the last survey point.

Preferences - Default Switches Input Window

Changes made to the default switches become active once you exit the
Preferences dialog using the OK button. However, changes in the values will
not be reflected in any of the PCPUMP output until after you have recalculated
the results.

Default Tolerances
The Default Tolerances tab of the Preferences window allows you to specify
default values for the following program parameters:
Minimum pump volumetric efficiency: Controls the value that triggers the
warning message for a low pump volumetric efficiency in the Analysis
Calculation Messages.
Maximum pump speed: Controls the value that triggers the warning
message for a high pump speed in the Analysis Calculation Messages.
Maximum pump differential pressure: Controls the value that triggers the
warning message for a high differential pump pressure in the Analysis
Calculation Messages.
Minimum equipment clearance in casing: Controls the value that triggers
the warning message for low clearances between the casing ID and
equipment OD in the Analysis Calculation Messages. The warning message
can be turned off completely by turning off the check box next to Minimum
equipment clearance in casing.
Minimum equipment clearance in tubing: Controls the value that triggers
the warning message for low clearances between the tubing ID and
equipment OD in the Analysis Calculation Messages. The warning message
can be turned off completely by turning off the check box next to Minimum
equipment clearance in tubing.
Maximum rod stress:
Controls the value that triggers the warning
message for a high rod stress in the Analysis Calculation Messages.
Maximum rod torque load: Controls the value that triggers the warning
message for a high rod torque load in the Analysis Calculation Messages.
Minimum electric motor load: Controls the value that triggers the warning

message for a low electric motor load in the Analysis Calculation Messages.
Maximum belt reduction ratio:
Controls the value that triggers the
warning message for a high belt reduction ratio in the Analysis Calculation
Messages.
Maximum tubing contact load:
Controls the value that triggers the
warning message for a high tubing contact load in the Analysis Calculation
Messages.
Minimum surface motor operating frequency: Controls the value that
triggers the warning message for a low surface motor operating frequency
in the Analysis Calculation Messages.
Maximum surface motor operating frequency: Controls the value that
triggers the warning message for a high surface motor operating frequency
in the Analysis Calculation Messages.
The defaults values are set to:
Minimum pump volumetric efficiency = 50%
Maximum pump speed = 500 RPM
Maximum pump differential pressure = 85%
Minimum equipment clearance in casing = 6.35 mm (0.25 in)
Minimum equipment clearance in tubing = 4 mm (0.2 in)
Maximum rod stress = 80%
Maximum rod torque load = 80%
Minimum electric motor load = 25%
Maximum belt reduction ratio = 6
Maximum tubing contact load = 445 N/m (30.5 lbf/ft)
Minimum surface motor operating frequency = 30 Hz
Maximum surface motor operating frequency = 90 Hz
The Load Defaults button can be used at any time to reset the tolerances to the
default values.

Preferences - Default Tolerances Input Window

Changes made to the default tolerances become active once you exit the
Preferences dialog using the OK button. However, changes in the values will
not be reflected in any of the PCPUMP output until after you have recalculated
the results.

Correlations
The Correlations tab in the Preferences window is for selecting default
multiphase fluid properties correlations. There are five properties for which
you can select a correlation. These are:
Dead Oil Viscosity: The viscosity of the oil with no dissolved gas in it.
Live Oil (Saturated) Viscosity: The viscosity of the oil when fully saturated
with gas (i.e. below the bubble point).
Undersaturated Oil Viscosity:
The viscosity of the oil when containing
some gas, but not fully saturated with gas (i.e. above the bubble point).
This should usually be between the dead oil and live oil viscosities.
Solution GOR: The amount of gas in solution in the oil.
Bubble Point: The pressure at which gas starts to come out of solution in
the oil.

Preferences - Correlations Input Window

Paths
The Paths tab of the Preferences window, shown below, allows you to specify
the location of program databases and saved files. You can either type in
paths directly or use the Browse button to search through your directory
structure until you locate the desired path. The following paths can be
specified within the Preferences window:
Saved Files: Default location of any data files you save.
Equipment Database: Location of the PCPUMP equipment database files. If
moved, the new location of the database files must be specified here for
the program to operate correctly.
Wellbore Geometry Files: Default location of any wellbore geometry files
that are imported or exported.
Custom Equipment Databases: Location of any custom equipment models
you create.
Equipment Test Data Files: Default location of any saved equipment test
data files, such as pump tests and motor tests.

Preferences - Paths Input Window

Regional
The Regional tab of the Preferences window, shown below, allows you to
specify the language you wish to work in. Available languages currently
include English, Russian, Chinese and Spanish. The regional options are
available only to licences that purchased the Language Module.

Preferences - Regional Input Window

You are here: Getting Started > Saving and Loading Data Files

Saving, Importing and Restoring Data Files

PCPUMP allows you to save and restore your assessments in the form of data
files. A single saved file contains all of the input information including
wellbore profiles, equipment specifications, fluid properties and operating
conditions.
To save a data file, simply click the File menu option, select "Save" and enter a
File name. If the file has been previously saved, PCPUMP uses that file name.
Clicking the File menu option and selecting "Save As" can be used to store an
existing file under a new name, or in a format which can be read by older
versions of PCPUMP. The default extension .pcp is recommended.
To open a data file, click the File menu option, select "Open" and select the
desired File name. Once you press the OK button in the Open window, the
information will be loaded and PCPUMP will load all of the wellbore, equipment,
fluid properties and operating conditions that were saved.

Autosave
PCPUMP will automatically create a backup file every time interval specified in
the Default Switches tab of the Preferences window. In the event that PCPUMP
shuts down without saving the current information, the backup file can be
loaded from "c:\documents and settings\<username>\local settings\temp\".
Note that you may need to enable the show hidden files feature in Windows
Explorer before this folder is visible. A backup file will have a .pcp.autosave
extension. The Autosave feature can be deactivated in the Preferences
window. More information on the autosave feature can be found in the Setting
Program Preferences section.

Importing
PCPUMP has the ability to import separate .pcp files into a single file. This
feature may be beneficial to users who wish to combine multiple systems into
a single file so that they can be compared. To combine two .pcp files, open the
first file, select "Import PCP File" from the File menu and select a second file to
import. Equipment cases with identical names will be modified to ensure that
each equipment case name is unique. Additional files can be imported by
repeating the above steps.

Backwards Compatibility

PCPUMP is backwards compatible to v2.0, meaning that it can open data files
saved by all previous versions after v2.0. The substantial differences in both
the program and the data structure do not allow PCPUMP to open old v1.0 and
v1.1 data files.
Older versions of PCPUMP may not be able to open files created using a newer
version. However, data files can be saved in a format that is compatible with a
previous version by clicking the File menu option, selecting "Save As", and
choosing the appropriate version using the drop-down list labelled Save as
type. Note that data files stored in an older version format may not contain
features specific to a newer version.

Save As Window

Related Topics
Setting Program
Preferences

You are here: Getting Started > Printing Data Files

Printing Reports
Most of the windows, dialog boxes and charts in PCPUMP can be printed using
the Report Selection window. This window can be accessed by clicking the File
menu option and selecting "Print", clicking the print command button
, or
pressing Ctrl+P.

Report Selection Window

The Report Selection window enables users to compile reports from different
windows in the program. To compile a report, move the desired components of
the report from the "Report Components" panel to the "Selected Report
Components" panel. The selected components in the "Selected Report
Components" can be rearranged using the two arrow buttons on the right-side
of the panel. This allows the components to be arranged in any order in the
report.
Once the report is arranged, users can print reports for multiple cases. Using
the "Cases" panel, check each of the cases for which reports are to be printed.
Users are given the choice to Save As PDF or Send to Printer. If multiple cases are
selected, each case will printed serially. If the Save As PDF option is selected,
each case will be placed in a separate file.
The following windows, tables, and charts are available in the "Report
Components" panel:
Wellbore
Wellbore Geometry Summary
Wellbore Geometry Table
Wellbore Geometry Charts
Measured Depth vs Dogleg Severity
Measured Depth vs Hole Angle
Measured Depth vs Hole Angle Change
Measured Depth vs Azimuth
Plan View
Vertical Section
Measured Depth vs Vertical Depth
Wellbore Curvature Components

3-D Wellbore Geometry

Well Design Summary
Equipment
Wellbore Completion Diagram
Pump Summary
Pump Test
Pump Performance Details
Pump Test Charts
Total Torque vs. Differential Pressure
Measured Volumetric Efficiency vs. Differential Pressure
Fluid Flow Rate vs. Differential Pressure
Fluid Slippage vs. Differential Pressure
Adjusted Volumetric Efficiency vs. Differential Pressure
Friction Torque vs. Differential Pressure
Total Power vs. Differential Pressure
Mechanical Efficiency vs. Differential Pressure
Fluid Flow Rate vs. Pumps Speed
Efficiencies vs. Pump Speed (at target pressure)
Rod String Details
Fluid Properties
Produced Fluid Properties
Advanced Fluid Viscosity Charts
Temperature Effects on Viscosity
Temperature and Shear Rate Effects on viscosity
Temperature and BS&W Content Effects on Viscosity
Shear Rate Effects on Viscosity
BS&W Content Effects on Viscosity
Diluent Fluid Properties
Advanced Diluent Viscosity Charts
Operating Conditions
Operating Conditions
IPR
Producing Fluid Temperature Profile
Analysis Results
Analysis Results - Summary
Analysis Results - Energy Flow

Analysis Results - Drive Equipment

Analysis Results - Basic Fluid Flow
Pressure Profiles
Tubing Pressure Components
Tubing Flow Losses
Temperature and Viscosity Profiles
Analysis Results - Rod Loading/Deflection
Rod String Torque and Axial Load Profiles
Rod String Effective Stress Profile
Elastic Based Rod String Design
Deformation Based Rod String Design
Rod String Torque Loading
Rod String Design Factors
Rod String Torque Breakdown (Incremental)
Rod String Torque Breakdown (Cumulative)
Rod String Deflection and Rotation
Rod String Space Out
Analysis Results - Rod/Tubing Contact
Rod/Tubing Contact Loads
Rod/Tubing Distributed Contact Loads
Rod/Tubing Contact Locations
Rod Guide Loading and Spacing
Analysis Results - Multiphase Flow
In-Situ Flow Rates
Produced Gas
Solution Gas
Flow Pattern
Liquid Holdup
Analysis Results - Key Locations
Auxiliary Analysis
Rod/Tubing Wear
Rod/Tubing Wear Summary
Tubing Wear Profile 1 Chart
Tubing Wear Profile 2 Chart
Tubing Wear vs. Time
Rod String Fatigue

Rod String Fatigue Summary

Measured Depth vs. Life Chart
Minimum Life vs. Torque Amplitude Chart
Minimum Life vs. Axial Load Amplitude Chart
Backspin
Backspin Summary
Brake Specification Summary
Backspin Response Chart
Fluid Level Response Chart
Braking Response Chart
Sensitivity - Peak Speed Chart
Sensitivity - Time and Temperature Chart

Related Topics
Exporting Data

You are here: Getting Started > Exporting Data Files

Exporting Data
PCPUMP has the ability to save the results of a calculation to an XML output
file. To export a data file, simply select "Export" from the File menu. This
should be done after completing a calculation in PCPUMP. Note that the export
feature will export data for the selected case at the selected batch value.
The export feature will generate two XML files. The first is a large, detailed
file, and the other is a smaller file containing the basic information which can
be viewed within PCPUMP, and which can be opened in Microsoft Excel (or
some other spreadsheet programs, such as Open Office) as a tabbed
spreadsheet. This file cannot be opened in versions of Microsoft Excel earlier
than Excel 2003. For most purposes, the smaller file will be all that is
required. If you wish to access more information than is available in the small
file, please contact CFER.

Related Topics
Printing Reports

You are here: Getting Started > Using Charts and Tables

Using Tables and Charts

Tables
Inputs are often specified using tables. The following features are available on
each table:
Insert Row: To insert a row in a table, select the row below where you
wish to insert a new row, right-click and select "Insert Row";
Delete Row(s): To delete one or more rows from a table, highlight the
rows you wish to delete, right-click and select "Delete Row(s)".
Clear All Rows: To clear the table, right-click and select "Clear All Rows".
Sort Rows: To sort the table, click on the header of the column you wish
to sort the table by. This feature has been disabled on some tables (e.g.
Wellbore Geometry).

Example of Input Table

Charts
The large portion of the analysis results in PCPUMP are shown using charts.
You can use the following features to help in evaluating the data presented in
a chart:
Toolbar: The toolbar is located above the chart and allows you to modify
the type and style of the chart. It also allows you to save chart settings,
output the chart to a clipboard, and print charts to PDF or a printer.
Note: You can view the toolbar by right-clicking anywhere in the chart
area and selecting "Toolbar".
Data Information: When the mouse is positioned over an element in the
chart (point or line), that element will become highlighted and a text box
will appear with information on the highlighted element.
Axis Information: When the mouse is positioned over an axis, a vertical
or horizontal line is shown intersecting the chart. All elements positioned

to the right or above the line will be highlighted. This option is useful when
identifying elements greater than a particular value.
Axis ranges can be modified by placing the cursor over the axis you want
to change and right-clicking. A list of options will appear, where the
"Properties" option will allow you to update the axis range.

Example of Analysis Output Chart

You are here: Getting Started > Feedback Form

Feedback Form
PCPUMP gives the user the ability to send feedback to the Technical Support
Team or to request technical assistance from within the program.
To send general comments, report a problem, ask a question or suggest an
enhancement, you can click on the email icon in the main program window
or select "Feedback" from the Help menu.
The same form can be accessed by clicking on the link found at the bottom of
the Analysis Calculation Messages window and the Summary tab of the Analysis
Results tab to request technical assistance should an error message appear
that is not clear or if the software generates an unexpected error.

PC-PUMP Feedback Form

You are here: Analysis Input Windows > Analysis Inputs Overview

Analysis Inputs Overview

The analysis input windows are composed of the Wellbore Geometry tab, the
Equipment Configuration tab, the Fluid Properties tab, the Operating Conditions
tab, and the Options tab. Different input configurations can be stored using the
Case Manager, located on the right-side of the main window.
Note: In each tab many of the inputs are optional and can be left out
depending on the analysis you wish to perform.
Once the analysis inputs have been entered and saved in one or more cases,
an analysis can be performed. A batch comparison can be performed by
entering information into the Batch Parameter section of the main window.

Related Topics
Wellbore Geometry
Equipment Configuration
Fluid Properties
Operating Conditions
Analysis Options
Case Manager

You are here: Analysis Input Windows > Specifying Project Information

Specifying Project Information

If you wish to save project details in your working data files and on your
printed output reports, you can do so using the PCPUMP Project Information
window. This window can be accessed by clicking the File menu option and
selecting "Project Information".

Project Information Window

The following fields are available for specifying project information:

Project Name: The name of the project you are working on.
The
information in this data field will be printed as the center header on every
output report printed from PCPUMP when you are using the active file.
Well Name: The name of the well being analyzed.
Created By: The person or company who created the PCPUMP data file.
Modification Date: The date of the latest modifications to the data file. This
data field is automatically filled in by the program.
Program Version: The version of the program used when the file was last
saved.
Comments: Any other information you wish to attach to the file.

You are here: Analysis Input Windows > Wellbore Geometry > Wellbore Geometry

Wellbore Geometry
When assessing a directional well, it is important to have an accurate
representation of its wellbore geometry. During drilling, or in some cases after
the well has been completed, a directional survey is obtained. A survey
consists of a series of measured depth, hole angle and azimuth measurements
taken from surface to the bottomhole location.
By processing survey data using a standard calculation procedure
(seeDirectional Wellbores - Technical Considerations), an array of parameters
that characterize a well's directional profile can be generated.
The wellbore profile is specified in the Wellbore Geometry tab found in the
main window.

Wellbore Geometry Table Input Window

Specifying a Kelly Bushing Offset

When a directional survey is performed, the depths on the survey are
measured from the Kelly Bushing (KB) elevation of the rig used to drill the
well, which is normally 3-15 metres above the ground surface. The Kelly
Bushing offset is then the distance between the Kelly Bushing elevation and
the casing flange. This offset (between the KB elevation and the casing flange)
can have an impact on the correct placement of rod guides in the well.
In a vertical well, or in wells in which rod guides will not be used, it is not
usually necessary to consider this offset, and a value of 0 can normally be
used.
The Kelly Bushing Offset is specified at the top of the Wellbore Geometry tab.

Specifying a Wellbore Geometry

In the Wellbore Geometry tab, there are three ways to specify a wellbore
geometry.
Table Mode
The Table tab contains three input columns (white) and a series of

calculated columns (grey). More information on the calculated columns is

presented below. The first column is the station number (Stn #) for each
row.
The three input columns are:
Measured Depth: Cumulative length along the wellbore.
Hole Angle: Inclination (drift angle) of the wellbore segment.
Azimuth: Direction (drift direction) of the wellbore segment.
Data for these three columns can be entered manually, or copied and
pasted from a spreadsheet file.
To enter survey data manually, input the Measured Depth, Hole Angle
and Azimuth values for each survey station. Calculated parameters are
automatically updated once information for a survey station is entered.
Note: Measured Depth values must be entered in sequence from top
to bottom. Hole Angle values must be expressed as decimals. For
example, a hole angle in degrees and minutes (e.g. 3030') must be
converted to its decimal equivalent (e.g. 30.5). Similarly, Azimuth
values must be entered as decimal values measured clockwise in
degrees from the true north (0) position. For example, a bearing of
N3015'W must be entered as 329.75.
To copy survey data from a spreadsheet, such as Microsoft Excel, copy
only the cells containing the three input parameters (measured depth,
hole angle, and azimuth), and paste them into the table using Ctrl-v.
Blank survey stations can be inserted into the table by selecting the row
below the desired insertion point, right-clicking and selecting "Insert
Row". Survey stations can be deleted by highlighting their corresponding
rows, right-clicking and selecting "Delete Row(s)". To delete all survey
stations in the table, right-click and select "Clear All Rows".
Wellbore Design Mode
The Well Design mode is useful for specifying a wellbore geometry for a
proposed well. See Well Design Mode for steps to use the Well Design
mode to create a wellbore geometry.

Import Mode
Survey data can be imported directly into the wellbore geometry
spreadsheet, provided that it has either been previously exported in a
PCPUMPformat.
Note: A Kelly Bushing Offset can be defined at the top of the Wellbore
Geometry tab once the survey data has been imported.
This survey file import is done by clicking the Import button and selecting
the file. PCPUMP currently supports the following import formats:
XML Files: Reads PCPUMP V3.x exported XML wellbore files.
PCPUMP Format: Reads PCPUMP V1.0 and V1.1 saved wellbore files as
well as PCPUMP V2.x exported wellbore files.
Note: PC-PUMP no longer supports importing of text delimited files. To
import text delimited files, open them in Excel and copy them into the
Table tab.

Viewing Wellbore Geometry

When the survey data is entered, there are three ways to view the wellbore
profile.

Table Mode
The Table tab contains nine calculated columns (grey).
Dogleg Severity (Overall):
Three dimensional curvature of the
wellbore segment.
Dogleg Severity (Vertical): Vertical section curvature of the wellbore
segment.
Dogleg Severity (Plan): Plan view curvature of the wellbore segment.
Hole Angle Change:
Rate of hole angle change of the wellbore
segment.
Vertical Depth: Cumulative vertical depth of the wellbore.
Horizontal Distance:
Cumulative horizontal displacement of the
wellbore.
Latitude: Horizontal distance in the north (+) and south (-)direction.

Departure: Horizontal distance in the east (+) and west (-) direction.
Vertical Section: Horizontal distance projected on a vertical plane
defined by the wellbore's final azimuth.
All parameters are computed using the minimum curvature method. If
any of the calculated values appears to be in error, you should verify the
survey data that you have entered. Small errors in measured depth, hole
angle or azimuth can sometimes result in large errors in the calculated
parameters.
Chart Mode
The wellbore profile can also be viewed using the Chart tab.

Wellbore Geometry Chart Window

The Chart tab contains the following charts.

Measured Depth vs. Dogleg Severity;
Measured Depth vs. Hole Angle;
Measured Depth vs. Hole Angle Change;
Measured Depth vs. Azimuth;
Measured Depth vs. Temperature;
Plan View;
Vertical Section;
Measured Depth vs. Vertical Depth; and
Wellbore Curvature Components.
Summary Mode
Summary information of the wellbore profile can be viewed using the
Summary tab.

Wellbore Geometry Summary Information Window

The following parameters displayed in the Summary tab are based on the

survey data and summarize the basic well geometry:

Average Survey Interval: Average distance between survey stations.
Final Azimuth: Azimuth at the bottom of the well.
Final Hole Angle: Hole angle at the bottom of the well.
Horizontal Offset: Total horizontal distance of well from wellhead.
Total Measured Depth: Total length of well.
Total Vertical Depth: Total vertical depth of well.
Maximum Dogleg Severity: Maximum wellbore curvature.
Location of Maximum Dogleg Severity:
The depth at which the
maximum dogleg severity occurs.

3-D Wellbore Mode

The 3-D Wellbore tab contains a three-dimensional image of the wellbore
entered in the Table tab.

Wellbore Geometry 3-D Wellbore Window

Users can control the image using the buttons located to the right of the 3D wellbore, and can reset the view of the 3-D wellbore at any time using
the "Reset" button underneath the controls to the right of the 3-D
wellbore.
Users can also display a color map representing the dogleg severity along
the wellbore. The user can choose to enter the following when displaying
the color map:
Maximum Value: All parameter values over the maximum will be
displayed as red on the 3-D wellbore.
Minimum Value: All parameter values over the minimum will be
displayed as green on the 3-D wellbore.
The color map parameters can be reset at any time using the "Reset"
button underneath the controls for the color map.

Exporting Wellbore Geometry Files

Wellbore geometry data is stored as part of PCPUMP's standard file saving

procedure (see the Saving, Importing and Restoring Data Files section).
However, in some cases you may want to store the directional information
separately. Wellbore geometry data can be exported to disk files using the
Export button at the top of the Well Geometry window. PCPUMP currently
supports the following export formats:
PCPUMP Format: Exports files in .XML or .WBR PCPUMP format. Note that
only the .WBR format is compatible with V2.xx. Only the input parameters
(measured depth, hole angle and azimuth) are included in the exported
file.
Copy/Paste: It is possible to copy data from PCPUMP using Ctrl-c, and
paste it into a spreadsheet such as Microsoft Excel.
Note: PC-PUMP no longer supports exporting of text delimited files. To
export text delimited files, copy the values in the Table tab into Excel.

Related Topics
Well Design Mode
Directional Wellbores - Technical
Considerations
Using Tables and Charts
Printing Reports
Exporting Data

You are here: Analysis Input Windows > Wellbore Geometry > Wellbore Design Mode

Well Design Mode

When directional survey data is not available, PCPUMP's Well Design mode can
be used to create directional survey data.
The Well Design window is accessed from the main Wellbore Geometry window
by clicking the Well Design button at the top of the window.

Well Design Data Input Window

Specifying a Wellbore Geometry

The wellbore profile is constructed using a series of discrete segments.
1. In the section for Initial Values, the initial Hole Angle and initial Azimuth
can be entered. The initial hole angle allows wellbore profiles for slant
wells that are spudded non-vertically to be entered. Enter zero for wells
spudded vertically.
2. For each segment, enter a Segment Length, Build Rate and Plan Curvature
into the table. Positive build rates correspond to a wellbore that is
increasing angle while positive plan curvature corresponds to a wellbore
that is moving left to right in plan view. Values of zero may be specified
for build rate (for a vertical or tangent segment) or plan curvature (i.e. for
a segment straight in plan).
Segments can be inserted into the table by selecting the row below the
desired insertion point, right-clicking and selecting "Insert Row".
Segments can be deleted by highlighting their corresponding rows, rightclicking and selecting "Delete Row(s)". To delete all segments in the table,
right-click and select "Clear All Rows".
3. After information has been entered for a particular segment, the following
parameters are calculated:
Measured Depth

Hole Angle
Azimuth
Dogleg Severity
Vertical Depth
Horizontal Distance
Latitude
Departure
Note: With the exception of the Dogleg Severity, these are all cumulative
values.
A row at the bottom of the table shows the values at the bottom of the
specified well.
4. The well profile "Plan View" and "Vertical Depth vs. Horizontal Distance"
can be viewed graphically by selecting the Charts tab.

Well Design Chart Display Window

Once you have finalized a wellbore design, click the OK button. Based on your
specified inputs, a directional profile spaced at 10-metre intervals is generated
and you are subsequently transferred back into the main Wellbore Geometry
window.
To abort your design and return to the main window, click the

Related Topics
Wellbore Geometry
Directional Wellbores - Technical
Considerations
Using Tables and Charts
Printing Reports
Exporting Data

Cancel

button.

You are here: Analysis Input Windows > Wellbore Geometry > Directional Wellbores - Technical
Considerations

Directional Wellbores - Technical Considerations

Directional wellbores generally follow along a planned three-dimensional
trajectory to a predetermined bottomhole target. Their use is usually driven
by economic and environmental factors. Specific applications for directional
wellbores include horizontal wells, pad drilling and offshore platforms.
Directional wells are typically classified as either slant, deviated or horizontal
as illustrated below.

Directional Well Types

In evaluating PC pumping systems, an accurate representation of the

directional wellbore profile is essential, particularly if equipment wear is a
problem.
Important measures of wellbore geometry include wellbore
curvature (dogleg severity) as well as the measured depth versus vertical
depth relationship. For existing wells, directional surveys have usually been
completed during drilling. These surveys record the inclination (hole angle)
and direction (azimuth) at various depths (stations) along the wellbore. The
accuracy with which the recorded survey data represents the actual trajectory
of the wellbore depends highly on the distance between the survey stations
and the type of survey instrument used49.
PCPUMP uses the minimum curvature method for both analyzing directional
survey data and creating proposals within its Wellbore Design mode. This
method defines the wellbore path by fitting consecutive survey points onto a
circular arc which minimizes the maximum curvature.
The minimum
curvature method has been shown to have excellent accuracy and is suitable
for a wide range of both survey spacing and overall curvature9.

Related Topics
Appendix A: References
Wellbore Geometry
Well Design Mode

You are here: Analysis Input Windows > Equipment Configuration > Overview

Equipment Configuration
The Equipment Configuration tab is the second tab main area of program and
is the starting point for most of your assessments. It is also the first window
you see when starting PCPUMP. In this tab, you can select PCP or ESPCP under
the Artificial Lift Type area located at the top of the window.

PCP Equipment Configuration Window

ESPCP Equipment Configuration Window

Specifying Equipment
Equipment selection windows are used to select equipment from the
PCPUMP database.
By clicking on the update button
next to the various pump sections, you are
directed to input windows where you can select from the equipment listed in
drop-down lists. Details of the active equipment is listed below the drop-down
lists. Equipment selection options in the Equipment Configuration tab include:

Pump
Below the pump update button is the pump summary which displays the
rated displacement and rated differential pressure of the pump.
Rod String (Surface Drive Location Only)
Below the rod string update button is the rod string summary box which
displays a summary of your current rod string configuration. Identical rods
are grouped together for convenient display. For each rod grouping, the
top and bottom location, number of rods and individual configuration are
displayed.
Tubulars

Below the tubulars update button is the tubular summary box which
displays a summary of your current casing, tubing, injection tubing
(surface drive only), tail joint (surface drive only) and shroud (downhole
drive only) configuration. For each length of equipment selected, the top
and bottom location are displayed.
Surface Drive Equipment (Surface Drive Location Only)
Below the surface drive equipment update button is the Surface Drive
Equipment summary which displays a summary of your surface drive
equipment. The summary box displays general information on any of the
selected drivehead, belts and sheaves, hydraulic motor and pump, or
electric motor equipment.
Downhole Drive Equipment (Downhole Drive Location Only)
Below the downhole drive equipment update button is the downhole drive
equipment summary which displays a summary of your downhole drive
equipment. The summary box displays general information on any of the
selected drive assembly, motor or cable equipment.
Pump Seating Measured Depth
The pump seating depth is the measured depth at the bottom of the pump
stator.
See the section on Selecting a Pump Seating Depth to learn more about
selecting a pump seating depth.
Mid-Perforations Measured Depth
The mid-perforation depth is the depth of the perforated section of the well
that allows produced fluid to enter. PCPUMP assumes that all flow comes
from a single point in the well. Enter the middle of the perforated section
in the Measured Mid-Perforations field.
Note:PCPUMP does not currently perform calculations for flow approaching
the pump from multiple directions (when the pump is landed between two
perforated zones). In this case, you must estimate which area has more
flow and set the mid-perforation depth near that depth.

Note: For horizontal wells, consider where the majority of the flow is
entering. If you have an even distribution along the horizontal section,
then enter the measured depth mid way along the horizontal section. If
you have more flow entering from near the toe of the well, enter that
depth as the mid-perforations depth.

Note: All measured depths in PCPUMP are measured relative to the Kelly
Bushing; if the Kelly Bushing is not at the wellhead, an offset must be entered
in the Wellbore Geometry window.

Related Topics
Pump Selection
Rod String
Casing String
Tubing String
Diluent Injection Tubing
Selection
Tail Joint String
Shroud
Surface Drive Equipment
Downhole Drive Equipment
Selecting a Pump Seating Depth
Printing Reports
Exporting Data

You are here: Analysis Input Windows > Equipment Configuration > Selecting a Pump Seating Depth

Selecting a Pump Seating Depth

The pump seating depth is the measured depth at the bottom of the pump
stator. However, at what depth should a PC pump be landed?
A few considerations include:
Fluctuating Fluid Levels. The actual producing fluid level can vary and
may drop significantly during the life of the well. As well, run life can be
shortened if the fluid level drops to a point where the pump's cavities are
not being sufficiently filled.
Viscous Fluids. Viscous fluid can create inflow problems where cavities
are not completely filled (leading to reduced run life). This problem can be
reduced by increasing the fluid level over the pump which increases the
pump intake pressure.
Gassy Applications. In a gassy application, lower intake pressures can
result in more free gas at the pump intake, resulting in lower volumetric
efficiency and potentially a reduced run life. As above, the higher fluid
column, the greater the pressure available to combat this problem.
Seating Below Perforations. There are advantages to seating the pump
below the perforations.
If a goal is to maintain a pumped off well, the lowest stable fluid level
is at the perforations. In order to achieve and maintain this fluid level
without damaging the pump, the pump must be below the perforations.
In a gassy application, seating the pump below the perforations will
allow free gas to travel up the annulus and not into the pump. This
may not be the case if the downward fluid velocity in the annulus is
too high. To reduce the annular velocity, ensure that the top of the
pump should be below all of the perforations as the pump outer
diameter is generally larger than the tubing outer diameter.
In CHOPS (Cold Heavy Oil Production with Sand) applications, sand
must be produced through the pump in order to maintain oil

production. Due to its higher density, the sand moving with the fluid
has the tendency to settle out. If the pump is seated above the
perforations, sand may accumulate to the point where the perforations
become plugged. However, if the pump is below the perforations, the
sand will build up only to the pump intake.
Furthermore, when the clearance between the top of the sand and the
bottom of the pump becomes small, the fluid velocity increases, and
this helps prevent the sand from blocking the pump intake (so long as
the pump is running).
Seating Above Perforations. There are advantages to seating the pump
above the perforations.
When an ESP motor is used to drive a PC pump, flow must be directed
past the motor in order to prevent it from overheating. The simplest
way of accomplishing this is to seat the pump and the motor above the
perforations. If, for reasons such as those above, it is desired that the
pump be below the perforations, a shroud must be used around the
motor to direct flow past the motor before reaching the pump intake.
Note: PCPUMP will not allow a calculation to proceed if the pump with
a downhole motor is seated below the perforations unless there is a
shroud.
If there is very small clearance between the pump and the casing and
the pump is seated below the perforations, there can be significant
flow losses as the fluid moves past the pump to the intake (particularly
if the fluid is viscous or if the rate is high). In such cases, seating the
pump above the perforations can eliminate those flow losses.

Deviated or Horizontal Wells. In a deviated or horizontal well, it is wise

to set the pump in a "tangent" section (a relatively straight section, with
low dogleg severity) (Figure A). If the pump is set in a section of well with
high curvature, it can lead to fatigue failures in the rotor or severe tubing
wear problems just above the pump. The amount of curvature which is
acceptable depends on the length of the pump and the relative sizes of the
pump and casing. The important thing is that the pump itself is not curved
during operation.
Note: PCPUMP does not determine if the pump will be curved where it is

landed.

Figure A Pump Landed in Tangent Section

Seating in the Perforated Interval. When possible, the pump should not
be set in the perforated interval. In addition to the reason given above
(related to gas production), there have been cases where high velocity
flow containing solids coming out of the perforations has been suspected of
causing external damage to the pump. This comment does not apply to
sections of open hole or in a liner, but only to a perforated section of
casing.
Location of Pump Intake. If the pump is seated above the perforated,
lined, or open interval, and the hole angle increases just below the pump
seating interval, it is possible that the pump intake could be located on the
high side of the wellbore. Free gas would then preferentially enter the
pump intake rather than proceed up the annulus (Figure B).

Figure B Gas Entering Pump on High Side

You are here: Analysis Input Windows > Equipment Configuration > Pumps > Pumps

Pump Selection
The key component in any artificial lift pumping system is the bottomhole
pump. It strongly influences the operation and performance of the system,
and consequently has a significant impact on all of the other system
components.
For PC pump systems, there are numerous considerations related to pump
selection. The most important of these include:
required pumping capacity;
required lift;
temperature and fluid compatibility issues;
casing size limitations;
sand handling capabilities;
pump inflow behavior; and
torque and power limitations.
To address these issues, manufacturers offer a large number of different pump
models that collectively cover a wide range of specifications.

Selecting a Pump
A pump is selected using the Pump Selection window. This window is accessed
by clicking the Pump update button
in the Equipment Configuration window.

Pump Selection Input Window

1. Select a pump vendor from the Company drop-down list. You can select
"All Companies" to view all the pump models in the database.
Note: Some vendors may be listed twice to accommodate both their new
and old pump model designations.
2. Once a vendor is selected, the table below will then display all of the pump
models available from that vendor with their displacement and pressure
ratings. There are several factors which must be considered in selecting a

pump. These are discussed here.

Displacement: To select a displacement, the estimated flow rate and
pump speed are considered. The maximum flow rate is normally
controlled by the reservoir deliverability. The actual flow rate may be
less than the maximum, for various reasons. Pump speeds can be as
low as 30 RPM and as high as 500 RPM. The following table provides a
rough guideline for pump speed.
Viscosity
(cp)

Optimal Speed
Range (RPM)

Maximum Speed
(RPM)

<500

200 - 300

500

500 5000

150 - 200

400

>5000

100 - 150

250

With the estimated flow rate and speed determined, one more piece of
information is required, and that is the expected volumetric efficiency
under operating conditions in the field. This will be discussed in
further detail below. An estimate of the minimum required pump
displacement can then be determined:
Vp = (100 x q)/(Np x np)
Where:
Vp is the pump displacement, m/d/RPM
q is the flow rate, m/d
Np is the pump speed, RPM
np is the pump efficiency, %
After running PCPUMP, improvements to this estimate can be made by
taking note of the resulting flow rate (q) and pump speed (Np)

displayed in the Analysis Results window.

Pressure Rating: There are three factors to consider in the
determining pressure rating:
Hydrostatic Head. In most cases, hydrostatic head is the largest
contributor to the pump differential pressure. The simplest way of
estimating hydrostatic head is to multiply the pump depth (vertical
depth) by a hydrostatic gradient of 10 kPa/m or 0.43 psi/ft. This
assumes the fluid density is that of water, but this is good for a
first estimate. Unless there are large amounts of gas, produced
fluid densities will almost always be within 20% of this value.
If the well will not be pumped-off, this estimate of hydrostatic
pressure can be too high, as the fluid level in the casing annulus
serves to reduce the net hydrostatic pressure. In this case,
instead of multiplying the pump depth by the hydrostatic gradient,
multiply the vertical depth of the expected fluid level (when
producing at the desired rate) by the hydrostatic gradient. This
should not be done, however, if the well will produce large amounts
of gas up the casing annulusin this case, to be conservative, use
the pump seating depth, even with a high fluid level.
This
procedure gives an estimate which can be re-evaluated after a
PCPUMP analysis is performed.
Flow Losses. Flow losses can, in many cases, contribute
significantly to pump differential pressure. Without having done
the calculations, this can be difficult to estimate. If there is a high
water cut or the oil is light, the flow losses can be expected to be
small relative to the hydrostatic pressure. If the fluid is viscous
(as in a heavy oil well with low water cut or a well producing a
water-in-oil emulsion), the flow losses can be significant
(particularly if the rate is high and/or there is no gas). In some
cases, the flow losses can even exceed the hydrostatic pressure.
At the initial pump selection stage of a PCPUMP analysis, simply
make an estimate of whether the flow losses are expected to be
near zero, moderate (half the hydrostatic pressure), or significant
(the same as the hydrostatic pressure). As above, this procedure
gives an estimate which can be re-evaluated after a PCPUMP
analysis is performed.
Wellhead Differential Pressure. The differential pressure that

exists on the wellhead between the casing head and tubing head
(or flow line) also acts on the pump. If the casing annulus is
vented to atmosphere, but the tubing empties into a high pressure
flowline, the differential is the flow line pressure at the wellhead.
If, on the other hand, the casing is tied into the same flowline
(through a check valve), the differential wellhead pressure is near
zero, regardless of the flowline pressure.
The estimate of the required pressure rating is the sum of these three
pressure components.
Note: It is normally recommended that the differential pressure during
production operations be limited to 70-90% of the pump pressure
rating. Operating at higher pressures increases the risk of a short
run-life due to high slippage rates and more severe elastomer loading.
Operating at a low percentage of the rated pressure implies that there
is more friction torque than necessary.

3. OPTIONAL: The optional pump model filter allows the user to list only
those pumps that meet certain criteria. You can access this filter by
clicking the Filters title and using the following parameters:
Pressure Rating: Enter the desired range of pump pressure ratings.
Displacement: Select the Basic or Advanced displacement filter:
Basic: Enter the desired range of pump displacement ratings.
Advanced: Calculate the desired range of pump displacement ratings
by defining a range of target flow rates and pump speeds, as well
as a target volumetric efficiency.
Click the Ensure Pump Stator Fits in Casing button to list pumps whose
stators can fit through the specified casing string to the pump seating
depth.
Click the Ensure Pump Rotor Fits in Tubing button to list pumps whose rotors
can fit through the specified tubing string to the pump seating depth.
For convenience, PCPUMP will save the filter settings in the file.
4. OPTIONAL: You can also click Create Custom Pump to create new pumps that
can be added to your own custom pump database by inputting relevant
specifications. More information on adding custom pumps can be found in
the Custom Pumps page.

5. To select a specific pump model, select the pump model name.

Pump Specifications
Within the Details tab of the Pump Selection window, you can view
specifications of commercially available pumps. In addition, you can input and
analyse pump test information as well as use it to determine performance
characteristics for subsequent assessments.

Pump Selection Details Window

Specifications are displayed in the Details tab and are shown in graphical
format in the Chart tab. You are also able to assign pump characteristics
either through static inputs or by association with a pump test.
Pump parameters displayed are:
Nominal Pump Displacement: Nominal pump displacement in flow volume
per RPM per day at zero differential pressure.
Pump Pressure Rating: Rated differential pump pressure.
Pump Nominal Lift: Rated pump lift in terms of equivalent vertical head of
water.
Rotor Connection: Connection on the rotor head for attachment to the rod
string.
Stator Connection: Connection on the top of the stator for attachment to
the tubing string.
Pump Length: Total length of the pump not including tag bar/stop bushing
assemblies.
Pump Outside Diameter: Maximum outside diameter of the pump.
Swept Rotor Angle: Angle of the rotor helix.
At lower swept rotor angles, the rotor applies more force along the pump
axis than it does circumferentially, thus providing more effective cleaning
of solids from the cavities.
Note: This information is not available for multilobe pumps.
Cavity Flow Index:

Velocity of fluid flow through the pump cavities per

100 m3/day of production.

This index is a measure of the ability of fluids to flow into the pump intake,
with lower values indicating potential for improved viscous fluid inflow.
Note: This information is not available for multilobe pumps.
Pumps is supplied with the proper size orbit tubing:

Indicates if a pump includes a

larger diameter joint of tubing above the stator (known as orbit tubing).

Pump Selection Chart Window

The Chart tab contains a performance chart that can be switched between
three different views using the Chart drop-down list:
Nominal Fluid Flow Rate vs. Pump Speed: shows nominal fluid rates as a
function of pump speed (0 to 600 RPM) for several volumetric pump
efficiencies.
Note: If a static volumetric efficiency is entered for the selected pump,
then the performance curves for that volumetric efficiency are also list.
Shaft Power vs. Differential Pressure: shows shaft power as a function of
pump differential pressure for several pump speeds (0 to 600 RPM).
Torque vs. Differential Pressure: shows hydraulic torque and total torque
as a function of pump differential pressure. Total torque is calculated by
adding the friction torque to the hydraulic torque.
Pump bench tests are performed to quantify the performance characteristics of
new and used pumps (see Pump Test Information). Based on these empirical
tests, values are usually determined for pump efficiency and pump friction
over a range of operating conditions (speeds, pressures and temperatures).
These parameters have a significant impact on pump and overall system
performance. When performing assessments with PCPUMP, you have the
option of specifying static values for these parameters or inputting pump test
information from which they can be calculated dynamically based on the
specified operating conditions.
To input or change the static values, use the edit boxes in the lower portion of
the window. Note that when a new pump is selected, these parameters are
assigned values based on the defaults you have set in the Preferences
window.

In order to have volumetric efficiency and friction torque values assigned

dynamically, you must choose a pump test by selecting Specify Test Data under
the Pump Performance section in the Details tab. This will take you to the
Pump Test Information window where all the tests associated with the
currently selected pump model are listed. If pump test information is not
available but the relationship between the pump differential pressure and the
pump efficiency is known, then that information can be entered using the
Specify variable volumetric efficiency option.
Once you have finished, click OK to close the Pump Selection input window. All
inputs are automatically saved.

Additional Considerations when Selecting a Pump

Volumetric Efficiency and Friction Torque
After selecting a pump model in PCPUMP, you must enter the expected
operating volumetric efficiency and friction torque. These cannot be
determined for you by the program. Estimates of these values can be
obtained from a pump bench test, but it is important to recognize that
bench test results may not be representative of the downhole behaviour. A
bench test is a short term test performed with water. Downhole, the
elastomer can swell due to fluid interaction and/or temperature increase.
This will affect both the friction torque and volumetric efficiency during
operation. In addition, the fluid itself can affect these parameters. For
example with high viscosity fluids, the volumetric efficiency may be higher,
unless there is an inflow problem, in which case the volumetric efficiency
can be reduced. Field experience can be very valuable in determining how
the friction torque and volumetric efficiency may change from the bench
test to the well. Different elastomers can react very differently to the
same downhole environment. The use of different rotor sizes, where the
minor diameter of the rotor has been increased or decreased by very small
amounts to adjust the interference fit between the rotor and stator, will
affect the volumetric efficiency and torque, both on the bench test and
downhole.
Swept Rotor Angle and Cavity Inflow Index
In the PCPUMP selection window, after a pump is selected, there are
displayed values for "swept rotor angle" and "cavity inflow index". These
pump characteristic indices are important in applications with produced
sand and very viscous oil, respectively. Within a pump company, or

between different companies, you will find that there are pumps with
similar displacements, but with very different geometries. Pumps which
have relatively short pitch lengths and larger cavity cross-sectional areas
are better suited, in general, to producing viscous oil or sand. When
trying to determine which pump model may be better for one of these
applications, look at the swept rotor angle (for sand) or the cavity inflow
index (for viscous oil). If two pump models have similar displacements,
the one with the smaller value of swept rotor angle or cavity inflow index
is likely better suited to these applications. Note, however, that pumps
with long pitch lengths will generally have a smaller OD and be longer
than pumps with short pitch lengths having similar displacement and
pressure rating.
Casing and Tubing Drift Diameter
You must be sure that your pump will physically fit in the well. PCPUMP
reports the OD of the pump; this must be less than the drift diameter of
the casing (drift diameters are not displayed in PCPUMP, but can be found
in commonly available casing tables). PCPUMP will give an error message
if this condition is not met. Be careful, however, because in many
applications you may need additional clearanceit is not enough for the
pump to just fit inside the casing. The main cases where this can be a
problem are as follows:
If there are significant flow losses (due to high rates or viscous fluids)
and the pump is below the perforations, the fluid must pass between
the pump OD and the casing; a tight clearance can result in significant
flow losses, even if this isn't a significant problem elsewhere in the
well.
In situations where the pump is seated above the perforations and the
well produces significant volumes of gas, there will be very little room
for free gas to pass by the pump and go up the casing annulus,
resulting in more gas being produced through the pump. PCPUMP will
consider this if the "Calculate Free Gas Separation" option is used.
In addition, the rotor's major diameter must be less than the drift diameter
of the selected tubing. If it is not, PCPUMP will give a warning message,
but will allow the calculation to proceed (as there are some on-off tools
available, which would allow the rotor to be run into the well with the
stator, and the rods latched on to it later).

Elastomer
Material selection is often critical in getting long run lives in PC pump
applications. This is especially true for the stator elastomer. Be aware,
however, that PCPUMP does not consider these issues. It requires field
experience and, in the absence of field experience, the selection of a
suitable elastomer based on compatibility test results from a laboratory.

Related Topics
Equipment Configuration
Variable Volumetric Efficiency
Pump Test Information
Custom Pumps
Stator Swell
Using Tables and Charts
Printing Reports

You are here: Analysis Input Windows > Equipment Configuration > Pumps > Variable Efficiency

Variable Volumetric Efficiency

A progressing cavity pump does not operate at a constant volumetric efficiency
when in operation downhole. As the differential pressure across the pump
increases, the volumetric efficiency decreases, and as the speed increases, the
volumetric efficiency increases.
Specifying the variable volumetric efficiency is preferable to entering a
constant value as this value assumes that the user can predict the downhole
efficiency of the pump. (This could involve some iterationfor example, the
user can enter an efficiency, and adjust it on subsequent runs until it matches
what he would expect at the given speed and differential pressure.)
Entering variable volumetric efficiency may also be preferable to using bench
test information because bench test results are normally from tests in water
for short periods of time. This means that they may be less accurate for oil,
especially after the elastomer has undergone swelling after being in the well
for a period of time.
The variable volumetric efficiency is specified using the Variable Volumetric
Efficiency window, which is accessed from the Pump window by selecting Specify
variable volumetric efficiency and clicking Specify.

Variable Volumetric Efficiency Input Window

Specifying Variable Volumetric Efficiency

1. Select the first check-box under Input Data if the
speed.

Efficiency varies with pump

Enter the Speed 1 to view the efficiency curve at that speed.

OPTIONAL: You can enter a second speed by checking the box next to
Speed 2 to see the efficiency curve at that speed. Note that the second
speed does not affect the calculation.

2. Select the second check-box under Input Data if the

differential pressure.

Efficiency varies with pump

Enter the Efficiency at zero pressure and the Efficiency at rated pressure.

Once you have finished, click OK to close the Variable Volumetric Efficiency
input window and return to the Pump Selection window. All inputs are
automatically saved.

Related Topics
Pump Selection
Equipment Configuration
Analysis Inputs Overview
Using Tables and Charts
Printing Reports

You are here: Analysis Input Windows > Equipment Configuration > Pumps > Pump Test Information

Pump Test Information

Pump tests are completed on new pumps to size them appropriately for their
intended application. Used pumps are tested to establish whether their
performance is adequate to warrant reuse. Sizing guidelines usually consist of
a range of acceptable volumetric efficiencies at rated pressure (or some other
reference pressure), as measured on a test bench under specified conditions.
Sizing guidelines have been developed largely on the basis of experience for
most field applications and the guidelines used by individual vendors typically
apply only to their products.
In a typical PC pump test, the pump is installed horizontally on a test bench
and used to pump water through a closed loop system. The intake pressure is
usually fixed at a low value and a choke on the discharge is used to regulate
the pump differential pressure. The test process consists of varying the
discharge pressure while operating the pump at one or more constant speeds.
In addition to monitoring the controlled pressure and speed, the torque and
fluid rate are also measured.
Pump test data is usually compiled into a summary report that is provided to
the purchaser. Besides listing the controlled and measured values, these
reports may contain other calculated parameters such as volumetric efficiency,
power and total efficiency. The format of these reports and the displayed
parameters tends to vary among the different pump vendors. Most reports
contain a chart similar in format to the one below.

Typical Pump Test Data

The user should exercise caution when using pump test data to determine
pump characteristics for PC pumping system assessments. In many cases,
bench test data is not representative of the pump's performance in the actual
downhole operating environment. For example, bench test measurements
correspond to water at a specific temperature. When installed in the field,
differences in the fluid characteristics (e.g. composition, temperature) may
cause elastomer swelling, shrinkage or expansion. These elastomer changes
can cause pump volumetric efficiency and friction values to vary significantly
from those measured on the test bench. During the sizing process, these

variations are taken into consideration. Although you may want to examine
these types of pump tests using PCPUMP, it is recommended that you do not
use the test data for completing system designs unless you have evidence to
show that the pump characteristics will not change in service.
To access the Pump Test Information input window, select the Equipment
Configuration tab, then click on the Pump update button . Within the Details
tab of the Pump Selection window, select Specify Test Data and click the Specify
button.

Pump Test Information Input Window

Specifying Pump Test Information

1. The top of the window displays the Pump Model that the test information is
for.
2. The Pump Test Name drop-down list will display all pump tests associated
with the selected pump model. If an existing pump test is selected to be
edited, proceed to Step 4.
3. To create a new pump test, click the Create File button. This will bring up a
dialog box into which you must enter a Pump Test Name and a File Name.
Although a file name is automatically created, you can modify it within the
lower edit box. When finished, click the OK button and you will be
returned to the Pump Test Information window along with a blank pump
test table.

4. To enter pump test data, enter Pump Speed, Differential Pressure, Total
Torque and Volumetric Efficiency information for each test point. You can
remove data from the table by selecting the cell, right-clicking, and
selecting "Delete Row(s)". To clear the entire table, right-click, and select
"Clear All Rows". Note that the data points are automatically sorted by
increasing speed and differential pressure.
5. The following parameters are displayed in the pump test table columns

from left to right:

Pump Speed*: Pump test speed.
Differential Pressure*: Pump differential pressure.
Total Torque*: Total measured pump torque.
Volumetric Efficiency*: Volumetric pump efficiency determined based
on the actual pump displacement.
Fluid Flow Rate: Fluid rate.
Fluid Slippage: Rate of fluid leakage across the rotor/stator seal lines.
Adjusted Volumetric Efficiency:
Volumetric pump efficiency is
determined using the calculated actual pump displacement at zero
differential pressure.
Hydraulic Torque:
Torque required by the pump to produce the
measured fluid rate across the differential pressure.
Friction Torque:
Pump torque used to overcome the mechanical
rotor/stator friction as well as hydraulic losses within the pump.
Effective Power: Quantity of power required to generate the hydraulic
torque.
Actual Power: Total power required to rotate the pump.
Total Efficiency: Total mechanical efficiency of the pump.
Note: The asterisked (*) parameters above
parameters. The others are calculated from these.

represent

the

input

6. In addition to the parameters calculated and displayed in the table,

PCPUMP also outputs several summary parameters in the list box below the
table. Included in this area are the following parameters:
Nominal Pump Displacement:
Nominal fluid flow rate per
revolution (RPM) at zero differential pressure.
Actual Pump Displacement: Pump displacement calculated based on
obtaining 100% volumetric efficiency at zero differential pressure. If
test data is input for multiple speeds, the average displacement at zero
differential pressure is displayed.
Nominal Pressure Rating: Rated differential pump pressure.
Average Friction Torque: Average friction torque at all test points.
Volumetric Efficiency at Pump Pressure Rating:
Volumetric
efficiency at the pump pressure rating calculated based on the actual
pump displacement. (Values displayed for each different test speed.)

7. You can also examine the pump test information graphically by selecting
the Chart tab. Using the Chart drop-down list, you can display the
following charts:
Total Torque vs. Differential Pressure;
Measured Volumetric Efficiency vs. Differential Pressure;
Fluid Rate vs. Differential Pressure;
Fluid Slippage vs. Differential Pressure;
Adjusted Volumetric Efficiency vs. Differential Pressure;
Friction Torque vs. Differential Pressure;
Total Power vs. Differential Pressure;
Mechanical Efficiency vs. Differential Pressure;
Fluid Rate vs. Pump Speed; and
Efficiencies vs. Pump Speed (at Target Pressure).

Pump Test Information Chart Window

8. The Pump Test Information window also permits you to calculate

performance characteristics at a Target Pump Speed and Target Differential
Pressure. Simply enter the target conditions into the two edit boxes below
the table. After both data points have been entered, a new data point that
represents your target conditions will be added at the bottom of the table.
In addition, most of the charts will also contain an additional data series
that corresponds to the target conditions. Use caution when specifying the
target condition inputs; values that are too far away from the test data
range may result in unreliable extrapolations.
Once you have finished, click OK to close the Pump Test Information input
window. All inputs are automatically saved.

Related Topics
Pump Selection
Equipment Configuration
Analysis Inputs Overview
Using Tables and Charts

Printing Reports

You are here: Analysis Input Windows > Equipment Configuration > Pumps > Custom Pumps

Custom Pumps
You can create new pump models that can be added to your own custom
databases. These pumps can subsequently be selected and used in the same
manner as any of the pumps included in the manufacturers' equipment
database
You can add custom pumps by clicking the Create Custom Pump button in the
Pump Selection window. This window can be accessed by clicking the Pump
update button
in the Equipment Configuration window.

Custom Pump Input Window

Specifying Custom Pump Information

1. On the left-side of the Custom Equipment window, you can select a custom
pump database. Each database may contain one or more custom pump
models. Once a database is selected, the names of these models will
appear under it. Highlighting a particular pump model will display the
specifications of the selected model. If an existing pump model is selected
to be edited, proceed to Step 4.
2. To create a new custom pump database, select "Pump" and click the Add File
button. This will bring up a window into which you must enter a Pump
Description and a File Name. Although a file name is automatically
created, you can modify it within the lower edit box. When finished, click
the OK button.

New File: Custom Pump Window

3. Once a file has been created, new custom pump models can be created by
right-clicking on the file name and selecting the "Add Model" option.
Alternatively, you can duplicate an exiting model by selecting a Pump

model, right-clicking, and selecting "Duplicate Model". When you have

added a new model to the file, you can enter or update the model
specifications located on the right-side of the screen.

Custom Pump Model Input Window

4. The following specifications are required for custom pumps:

Pump Type: Specify if pump is single lobe, multilobe (Moineau type) or
multilobe (modified type).
Nominal Pump Displacement:
Nominal pump displacement per
revolution (RPM) per day at zero differential pressure.
Pump Pressure Rating: Rated differential pump pressure.
Rotor Head Connection: Connection on the rotor head for attachment
to the rod string (e.g. 25.4 mm API Pin).
Stator Connection: Connection on the top of the stator for attachment
to the tubing string (e.g. 73.0 mm EUE Box).
Pump Length: Total length of the pump not including tag bar/stop
bushing assemblies.
Pump Outside Diameter: Maximum outside diameter of the pump (see
geometry diagram below).
Pump Coupling Outside Diameter: Maximum outside diameter of the
pump coupling.
Pump Eccentricity: Eccentricity of the pump (see geometry diagram
below).
Rotor Diameter: Nominal diameter of the rotor (see geometry diagram
below).
Rotor Long Axis: Nominal diameter of the rotor long axis (multilobe
pump only).
Rotor Short Axis: Nominal diameter of the rotor short axis (multilobe
pump only).
Rotor Pitch: Pitch length of the rotor helix (see geometry diagram
below).
Rotor Head Diameter: Maximum outer diameter of the rotor head
(connection to the rod string).

PC Pump Geometry (Single Lobe)

It is important to ensure that the values you input correspond to the units
of measurement that are currently selected.
5. The following parameters will be calculated and displayed in the bottom
portion of the screen:
Calculated Displacement: Pump displacement calculated on basis of
its fundamental geometry parameters.
Swept Rotor Angle: Angle of the rotor helix (for single lobe pumps
only).
At lower swept rotor angles, the rotor applies more force along the
pump axis than it does circumferentially, thus providing more effective
cleaning of solids from the cavities.
Cavity Inflow Index: Velocity of fluid flow through the pump cavities
per 100 m3/day production (for single lobe pumps only).
This index is a measure of the ability of fluids to flow into the pump
intake, with lower values indicating potential for improved viscous fluid
inflow.
6. Pump is supplied with the proper size tubing drop-down box: Used to
indicate if the pump includes a larger diameter joint of tubing above the
stator (known as an orbit tube).
7. To remove a pump from a database, select it by highlighting its name,
right-click the mouse and select "Delete Model".
Once you have finished, click OK to close the Custom Equipment input
window. All of the new custom pump databases and their corresponding pump
models will now be available for selection and use throughout PCPUMP.

Related Topics
Pump Selection
Equipment Configuration
Analysis Inputs Overview

Using Tables and Charts

Printing Reports
Custom Equipment Encryption

You are here: Analysis Input Windows > Equipment Configuration > Pumps > Stator Swell

Stator Swell
In most cases, the common pump sizing practices used in the industry are
based on selecting a rotor/stator combination that meets predetermined
criteria in a pump bench test. While sizing guidelines developed by operators
and pump suppliers do take into account expected downhole conditions,
laboratory tests are often conducted to better assess elastomer swell and
chemical compatibility. Results of these laboratory tests are usually presented
in terms of % swell of the elastomer samples, and need to be translated into
the expected interference fit, to help in pump sizing.
PCPUMP includes a tool to estimate how the interference fit of a single lobe
pump will be affected by elastomer swell. This tool can be accessed by clicking
Tools in the PCPUMP menu and selecting "Swell Model".

Swell Model Window

Specifying Stator Swell

1. Enter the pump Stator Minor Diameter and Rotor Minor Diameter.
Note: Different values for the stator and rotor minor diameters can be
entered to account for rotor over-sizing or rotor under-sizing.
2. Enter the pump rotor Eccentricity.
Range: The ratio of the pump stator minor diameter (D) to the pump
eccentricity (e) must be between 2 and 10. [i.e. 2 < D/e < 10 ]
3. Enter the stator Elastomer OD (outer diameter) - i.e. the inner diameter of
the stator barrel.
The stator elastomer outer diameter is the inside diameter of the tubing
housing the pump is molded in.

Range: The ratio of the cavity length (D +4e) to the elastomer outer
diameter (OD) must be between 0.70 and 0.97. [i.e. 0.70 < (D +4e)/OD
< 0.97 ]
Please see the Custom Pumps section for a description of these geometric
parameters.
4. Enter Poisson's Ratio between 0.45 - 0.49. Poisson's Ratio is the ratio,
when a sample object is stretched, of the contraction or transverse strain
(perpendicular to the applied load), to the extension or axial strain (in the
direction of the applied load).
5. Enter the expected percentage Swell between 0% and 6%.
6. Once all information is entered, the swollen shape of the stator elastomer
and the estimated interference fit are shown in the figure on the righthand panel.
The figure shows a cross section of the pump. The outside circumference of
the elastomer is shown in blue, the shape of the undeformed cavity (i.e. at
0% swell) in red, the shape of the cavity after the elastomer has swollen
in turquoise, and the rotor at the centre position in green.
7. In addition to the figure, the Maximum Interference and the End
Interference are calculated.
The maximum interference is the radial interference between the rotor
and the swollen stator elastomer when the rotor is at the centre of the
cavity (note that the diametric interference value would be twice this
value). This maximum interference equals the distance between the red
line and the magenta line at the middle of the graph (0 on the horizontal
axis).
The end interference is the distance the rotor must deform the swollen
stator at the end of the cavity, i.e. when the rotor is at the most eccentric
position.
Note that the swollen shape of the stator is calculated for a stator free to
expand without the presence of the rotor.

The ranges noted above are based on tests that were performed during the
development of the simplified swell model used within PCPUMP. Corrections
have been applied to make the simplified swell model agree with more
complex FEA models, and these corrections would be invalid outside the
ranges.
Some of the inputs relating to pump geometry are proprietary to the pump
companies. PCPUMP will therefore not provide these parameters from the pump
database for use in the Swell program. The only exception to this is when a
custom pump is being used, because these numbers are already accessible to
the user.

Related Topics
Pump Selection
Equipment
Configuration
Analysis Inputs
Overview
Using Tables and Charts
Printing Reports

You are here: Analysis Input Windows > Equipment Configuration > Tubulars > Casing Selection

Casing String
Every analysis case in PCPUMP requires a casing string that extends from the
deeper of the pump intake, mid-perforations or tail joint to surface. If your
well has multiple casing strings, only the innermost production string needs to
be entered into the program.
There may be cases where casing is set at a deeper depth and does not extend
to surface within the larger strings. For example, in horizontal wells the liners
are treated as casing strings in PCPUMP. In such cases, multiple sizes of casing
should be entered.
If there is a section of open hole (i.e. with no casing), a casing size with an ID
similar to the diameter of the open hole section should be selected.
PCPUMP does not consider multilaterals; if you have such a well, enter only the
main branch of the well, or the branch where the pump will be seated if
laterals are off a vertical or directional well.
The casing string is specified using the Tubulars window. This window can be
accessed by clicking the Tubulars update button
in the Equipment
Configuration window.

Casing Selection Input Window

Specifying a Casing String

1. Select a Casing Size and Weight from the drop-down list.
2. Enter the Length of the casing string. Casing segments are added from the
pump upwards to surface.
Note: The length field will be automatically pre-populated with the length
from the top of the casing string to surface.
The Top and Bottom positions of the casing segment will be automatically
calculated from the top of the lower casing segment or pump intake and

from the length value entered.

Note: If you enter a casing string that does not extend to surface or to the
pump intake, during the analysis PCPUMP will extend the top casing
segment to surface and the bottom segment to the lowest point in the
well.
3. Repeat the above steps to build a casing string with different diameter
casing sections.
To insert casing segments into the casing string, select the row above where
you wish to insert a casing segment, right-click and select "Insert Row".
To remove casing segments, select the unwanted rows, right-click and select
"Delete Row(s)". Alternatively, to remove all casing segments, right-click and
select "Clear All Rows".
Once you have finished specifying the casing string, click the OK button in the
bottom right-hand corner of the screen to confirm your inputs and return to
the Equipment Configuration window.

Related Topics
Equipment Configuration
Analysis Inputs Overview
Using Tables and Charts
Printing Reports

You are here: Analysis Input Windows > Equipment Configuration > Tubulars > Tubing Selection

Tubing String
In PC pump systems, a tubing string is used to transport produced fluids to
surface.
Every analysis case in PCPUMP requires a tubing string. The tubing string can
be composed of any number of different diameter tubing sections.
The tubing string is specified using the Tubulars window. This window can be
accessed by clicking the Tubular update button
in the Equipment
Configuration window.

Tubing Selection Input Window

Specifying a Tubing String

1. Select a tubing Brand, Size and Grade from the drop-down list. There are a
few things to consider in selecting tubing:
Flow Losses: The larger the tubing size, the lower the flow losses. In
an application with high flow losses, increasing the tubing size will help
reduce them.
Casing Drift: The selected tubing must fit within the casing in the
well. If the casing diameter in your well is small, this will limit the
tubing selection. The program will check to ensure the tubing collars
fit within the casing and give an error if they do not.
Tubing Weight: If you are using coiled tubing, the weights listed in
PCPUMP will not be accurate. Select a weight for which the EUE tubing
has OD, ID and drift diameters as close as possible to the desired size
of coiled tubing. Once the new weight has been selected, ensure that
the proper coupling OD is entered in the Coupling O.D. field as
described in step 3.

Sand Transport: The smaller the tubing, the higher the flow velocity
which will improve sand transport up the well. Sand transport is more
likely to be a problem when the fluid viscosity is low (high viscosity
fluid carries sand very well, even at lower velocities).
Lining: Tubing lined with high density polyethylene (HDPE) is
available from multiple vendors and offers benefits in applications
where tubing wear or corrosion are problems. In most cases, the
effect on flow losses of the reduced roughness of the HDPE is
outweighed by the reduction in flow area, as the lining reduces the ID
of the pipe. The change in surface roughness can be accounted for by
changing Tubing Roughness in the Default Values tab of the
Preferences window. The reduced ID also reduces the size of pump
rotor which can be run through the tubing.
Note: Brands of tubing other than API or non-API are lined tubing.

2. Enter the Length of the tubing string. Tubing segments are added from the
pump upwards to surface. The length from the top of the tubing string to
surface is entered as default by PCPUMP and can be edited.
The Top and Bottom positions of the tubing segment will be automatically
calculated from the top of the lower tubing segment or pump intake and
from the length value entered.
Note: If you enter a tubing string that does not extend to surface or to the
pump intake, during analysis PCPUMP will extend the top segment to
surface and the bottom segment to the pump intake.
3. The API standard coupling outer diameter for EUE tubing is entered into
Coupling O.D. by PCPUMP and can be edited if other jointed tubing or coiled
tubing is used. This information is used to evaluate if the tubing can be fit
into the selected casing and for cable clearance calculations in downhole
drive analyses.
4. Repeat the above steps to build a tubing string with different diameter
tubing sections.
To insert tubing segments into the tubing string, select the row above where
you wish to insert a tubing segment, right-click and select "Insert Row".

To remove tubing segments, select the unwanted rows, right-click, and select
"Delete Row(s)". Alternatively, to remove all tubing segments, right-click and
select "Clear All Rows".
Once you have finished specifying the tubing string, click the OK button in the
bottom right-hand corner of the screen to confirm your inputs and return to
the Equipment Configuration window.

Related Topics
Equipment Configuration
Analysis Inputs Overview
Using Tables and Charts
Printing Reports

You are here: Analysis Input Windows > Equipment Configuration > Tubulars > Diluent Injection Tubing
Selection

Diluent Injection Tubing Selection

In some PC pump systems, operators inject diluent downhole using an
injection tubing string in order to reduce flow losses, and thereby reduce
loading on the pump and other equipment.
CFER acknowledges SINCOR for contributing to the development of the
diluent injection feature in PCPUMP.
The tubing string is specified using the Tubulars window. This window can be
accessed by clicking the Tubulars update button
in the Equipment
Configuration window.

Injection Tubing Selection Input Window

Specifying an Injection Tubing String

1. Select the diluent Injection Location, which can either be "Into Casing" or
"Into Tubing". If you want to inject into a tail joint, select "Into Tubing".
2. Enter an Injection Nozzle Coefficient. The flow coefficient is used, in
conjunction with the nozzle size, to calculate the pressure drop across the
nozzle at the bottom of the injection tubing.
The relationship used to calculate the pressure loss across the injection
nozzle is:
P = (k x d x Q2)/(2 x A2)
Where:
Q is flow rate, m/s
d is density, kg/m
k is the nozzle coefficient (assume 1 for conservative results)
A is the nozzle area, m

P is the pressure loss, Pa

3. Enter the Injection Depth.
4. Enter the inner diameter of the injection nozzle into Nozzle Diameter. The
nozzle diameter is the size of the orifice in the injection nozzle at the
bottom of the diluent injection tubing string. If no nozzle is to be used,
enter the inner diameter of the injection tubing.
5. Select the injection tubing Size and Grade from the drop-down list. Once
you select a tubing type, the default coupling size appears in the boxes
next to the drop-down. You can edit this if it is not correct for your
particular tubing.
Otherwise, enter a custom size using the tubing inner diameter (Tubing
I.D.) and the tubing coupling outer diameter (Coupling O.D.) options in the
last two columns. If you are using continuous tubing, or non-upset tubing,
enter the tubing OD instead of the coupling OD.
Note: For some sizes the EUE coupling O.D. and for others it will be the
pipe O.D.
6. Enter the Length of the injection tubing string. As with tubing, the Top and
Bottom positions of the injection tubing segments are added from the
pump upwards to surface. PCPUMP will automatically add missing tubing or
remove excess tubing so that the string extends to surface.
7. Repeat steps 5 to 6 to build a tubing string with different diameter tubing
sections.
To insert injection tubing segments into the tubing string, select the row
above where you wish to insert an injection tubing segment, right-click and
select "Insert Row".
To remove injection tubing segments, select the unwanted rows, right-click,
and select "Delete Row(s)". Alternatively, to remove all injection tubing
segments, right-click and select "Clear All Rows".
Once you have finished specifying the injection tubing string, click the OK
button in the bottom right-hand corner of the screen to confirm your inputs
and return to the Equipment Configuration window.
Restrictions

Note that there are presently several restrictions on the use of the diluent
injection feature in PCPUMP:
Diluent injection can only be run with single-phase fluid properties.
Diluent injection can only be run for surface drive systems.
If injection is into the casing, the injection depth must be between the
mid-perforations depth and the intake point (pump seating depth or tail
joint intake depth).
If injection is into the tubing, the injection depth can not fall below the
intake point (pump or tail joint) or between the top and bottom of the
pump.
The injection tubing must fit into the casing along with the production
tubing.
Advanced viscosity (of the production fluid) with non-Newtonian effects is
not available with diluent injection.

Related Topics
Equipment Configuration
Analysis Inputs
Overview
Using Tables and Charts
Printing Reports

You are here: Analysis Input Windows > Equipment Configuration > Tubulars > Tail Joint Selection

Tail Joint String

In PC pump systems, a tail joint is a length of tubing placed below the pump.
The tail joint can be composed of any number of different diameter tail joint
sections.
The tail joint is specified using the Tubulars window. This window can be
accessed by clicking the Tubulars update button
in the Equipment
Configuration window.

Tail Joint Selection Input Window

Specifying a Tail Joint String

1. Select a tail joint Brand, Size and Grade from the drop-down list.
2. Enter the Length of the tail joint string. Tail joint segments are added
downward from the pump.
The Top and Bottom positions of the tail joint segment will be
automatically calculated from the bottom of the lower tail joint segment or
pump intake and from the length value entered.
3. The API standard coupling outer diameter for EUE tubing is entered into
Coupling O.D. by PCPUMP and can be edited if other jointed tubing or coiled
tubing is used. This information is used to evaluate if the tubing can be fit
into the selected casing and for cable clearance calculations in downhole
drive analyses.
4. Repeat the above steps to build a tail joint string with different diameter
tail joint sections.
To insert tail joint segments into the tail joint string, select the row above
where you wish to insert a tail joint segment, right-click and select "Insert
Row".

To remove tail joint segments, select the unwanted rows, right-click and
select "Delete Row(s)". Alternatively, to remove all tail joint segments, rightclick and select "Clear All Rows".
Once you have finished specifying the tail joint string, click the OK button in
the bottom right-hand corner of the screen to confirm your inputs and return
to the Equipment Configuration window.

Related Topics
Equipment Configuration
Analysis Inputs Overview
Using Tables and Charts
Printing Reports

You are here: Analysis Input Windows > Equipment Configuration > Tubulars > Shroud Selection

Shroud
In PC pump Systems with a downhole drive system, you can add a motor
shroud to redirect flow past the motor for cooling purposes. This is necessary if
the pump is to be landed below the perforations.
The shroud is specified using the Tubulars window. This window can be
accessed by clicking the Tubulars update button
in the Equipment
Configuration window.

Shroud Selection Input Window

Specifying a Shroud
1. Select Shroud Active and enter the Outer Diameter and Inner Diameter of
the shroud. PCPUMP assumes that the shroud extends from the pump
intake to the bottom of the motor.

Once you have finished specifying the shroud, click the OK button in the
bottom right-hand corner of the screen to confirm your inputs and return to
the Equipment Configuration window.

Related Topics
Equipment Configuration
Analysis Inputs Overview
Printing Reports

You are here: Analysis Input Windows > Equipment Configuration > Rods > Rod String Selection

Rod String
The rod string transmits torque from the surface drive equipment to the pump
rotor.
The rod string is specified using the Rod String Selection window. The Rod
String Selection window is accessed by clicking the Rod String update button
in the Equipment Configuration window.

Rod String Selection Input Window

The software constructs a rod string by adding rod segments, couplings, and
rod guides to the string from the pump rotor to the surface drive equipment. It
is not necessary to specify a polish rod and pony rods to get the correct length
to surface.

Specifying a Rod String

1. Under Rod Specification, from the rod Type drop-down list, choose
"Standard", "Continuous" or "Hollow rods".
Standard rods, such as described in API Specification 11B51, are used
in most wells.
Continuous rods are advantageous in deviated wells, as they greatly
reduce rod/tubing wear and fatigue problems. In addition, they can

also be run into (and out of) wells faster than standard rods.
Hollow rods are advantageous over other types as they have the
ability to pump diluent or other treatment chemicals down the hollow
space within them. (Note: Diluent injection through rods had not been
implemented in PCPUMP.) In some cases, people allow produced flow
to go up that space in addition to up the tubing, but PCPUMP cannot
currently consider this.
2. Choose a rod manufacturer from the Brand drop-down list.
"API" rods are generic rod conforming to API specification 11B. "Mod. API"
rods have non-standard pin connections but, otherwise, meet API
specification.
3. Select a rod Size and Grade from those in the corresponding drop-down
list. Non-standard pin connection sizes are available for "Mod. API" rods,
and for some particular brands.
Note: In general, you need to select a rod size which is large enough to
carry the loads applied during production operations. Rod sizes which are
larger than necessary will create additional flow losses.
4. The Yield Stress and Torque Limit fields display the rod yield stress limit
and torque limit.
If "API" or "mod. API" rods are chosen, you can specify the material yield
strength of the selected rod. The default value is the API minimum yield
strength for the specified rod grade (e.g. API grade D minimum strength =
586 MPa).
Note: It is a common recommendation that the rods be sized (considering
diameter, material strength, and connection size and capacity) so that the
expected operating torque is no more than 80% of the torque rating of the
rod. For rods which do not have a torque rating, ensure that the predicted
operating stress is less than 80% of the yield stress. In making an initial
rod selection, you can get an estimate of the torque (but not the stress)
from the Pump Selection window in PCPUMP. There is a chart which shows
how the selected pump's required torque will change based on differential
pressure. The maximum torque will be the torque at the rated pressure.
You can make an initial selection of the rod string based on this value.

5. Select a Coupling Type from those available in the drop-down list. Only
products that match the selected rod type and size will be displayed.
This option is not available for continuous or hollow rods.
Note: API couplings are available in full size or slimhole. Slimhole
couplings, when made-up correctly, are stronger than the rod body. The
main reason to use full size couplings is if they are less expensive than
slimhole couplings in your area. Slimhole couplings will serve to reduce
flow losses, so they should be used in applications where there are
substantial flow losses. Coated or spin-through couplings can be used to
reduce wear rates in deviated wells.
6. Select a rod length from those listed within the Length drop-down list. If a
specific rod length is not available, a value can be entered manually.
7. OPTIONAL: The specification of rod guides in the Rod Guide Specification
section of this window is optional and applies only to standard rods. Rod
guides are also used in deviated wells to reduce wear rates and increase
fatigue life.
If you wish to add rod guides, select a rod guide Type from those available
in the drop-down list.
Two options are available for determining the number of rod guides to
place on each rod:
To specify a constant number of rod guides to place on each sucker
rod, Specify the number of guides in the input area provided.
Alternatively, you can allow the software to determine the number of
rod guides on each sucker rod based on the rod/tubing contact force by
selecting Optimize number of guides.
This method is beneficial as contact loads tend to vary along the length
of a well (due to changes in well curvature and rod axial load). For
example, the vertical section near the top of a well may not require
any guides, whereas 3 or more guides may be necessary to mitigate
wear problems in the build section of the well.
When this option is selected, you specify the:

Maximum Contact Load per guide;

Minimum Number of Rod Guides; and
Maximum Number of Rod Guides.
When you add rod segments with this option activated, the rod guide
configuration in the table will initially appear in the format "OPT: ? x
<Rod Guide Type>". However, after you have performed a calculation
in the Analysis module, the ? will be replaced with the optimized
number of rod guides.
If you believe that both the couplings and rod guides may be in contact
with the tubing, then check the option Coupling/tubing contact occurs in addition to
rod guide/tubing contact. This option will tell the software to consider both
coupling and rod guide contact on the tubing wall.
Note: An error will result if this check-box is not selected and the rod
guide diameter is less than the coupling diameter.
8. Once the rod has been specified, it must be added to the rod string. There
are several ways to do this.
a. Repeatedly add the selected rod from the top of the existing rod string
to surface using the Fill to Surface button.
HINT: To replace the entire rod string with the selected rod, right-click
and select "Clear All Rows". Then select the Fill to Surface button.
b. Add the rod to the top of the existing rod string.
Once the rod is specified, to add the rod to the top of the rod string
select the Add to Top button and the following window will appear.

In the window you can select either Add individual rods or Add rods by
length. The Add individual rods option adds the specified number of
rods to the top of the rod string. The Add rods by length option adds
the corresponding number of rods that fills the specified length above
the top of the rod string.

c. Insert the rod into the middle of the existing rod string.
Once the rod is specified, select the row in the table below the
insertion location. Then select the Insert button and the following
window will appear.

In the window you can select either Add individual rods or Add rods by
length. The Add individual rods option inserts the specified number of
rods into the selected row of the rod string. The Add rods by length
option inserts the corresponding number of rods that fills the specified
length into the selected row of the rod string.
d. Replace an existing rod in the rod string with the selected rod using
the Replace button.
You can remove rods from the rod string by highlighting them, rightclicking and selecting "Delete Row(s)". To clear the entire rod string, rightclick and select "Clear All Rows".
9. Several features have been included to assist you in modifying the rod
string configuration. To quickly populate the information fields at the
bottom of the window, select a row from the table, right-click and choose
"Select above inputs using this rod". Alternatively, at the far left of each
row, an icon is available that when clicked will perform the same action
using the information contained on the row. If the rod, coupling or rod
guide characteristics have changed in the database since the file was last
saved, the program will generate a message informing you of such. The
program will continue to use the correct rod, coupling or rod guide data to
populate the information fields. If the selected rod, coupling or rod guide
is not found in the database then the program will stop the copy feature
leaving some information fields incomplete. If you receive a message,
please ensure that the information at the bottom of the rod string window
is correct before proceeding.

10. Repeat this process as often as necessary, choosing as many different

segment configurations as needed. It is good practice, however, to have
the final rod string extend all the way to surface or to the Kelly Bushing
Offset (if specified).

Once you have finished selecting a rod string, click the OK button in the bottom
right-hand corner of the screen to confirm your inputs and return to the
Equipment Configuration window.

Related Topics
Equipment Configuration
Analysis Inputs Overview
Using Tables and Charts
Printing Reports

You are here: Analysis Input Windows > Equipment Configuration > Surface Drive Equipment > Overview

Surface Drive Equipment

In a conventional PC pumping system, surface drive equipment transmits
power from the prime mover to the rod string. This equipment almost always
incorporates some gear reduction that permits the prime mover to operate at a
higher speed and lower torque than the pump. Drive equipment can be
arranged in a variety of configurations and can be comprised of several
different components as shown in the schematic below.

Typical Surface Drive Equipment Configurations

There are potentially three speed reductions between the motor shaft and the
polish rod. These are the belt ratio, the hydraulic displacement ratio, and the
drivehead gear ratio. To get the total reduction ratio, you need to multiply the
three ratios, as applicable. The gear and belt reductions are displayed or
entered directly.
To determine the hydraulic ratio, divide the motor
displacement by the pump displacement.
PCPUMP provides you with the option of including drive equipment in your
assessments.
To consider surface equipment, select the Equipment
Configuration tab at the top of the screen and select PCP under the Artificial Lift
Type section at the top left corner of the window. The Surface Drive Equipment
Selection window is accessed by clicking the Surface Drive Equipment update button
in the Equipment Configuration window.
If you wish to ignore drive equipment, just bypass this window. However,
when you do not specify a drive equipment configuration, some of the output
in the Analysis Results tab will not be available.
The tabs on the top of the Surface Drive Equipment Selection window can then
be used to move between the following four major surface drive equipment
components:
Drivehead;
Belts;
Hydraulics; and
Prime Mover.

It is recommended that you configure equipment starting at the drivehead and

proceed toward the prime mover. Although you must specify both a drivehead
and a prime mover, belts and hydraulics are optional components.
Once you have finalized selecting all the surface drive equipment components,
click the OK button to return to the Equipment Configuration window. A
summary of the chosen drive equipment will be displayed in a list box under
the Surface Drive Equipment update button.
To abort any changes made to the drive equipment configuration and return to
the Equipment Configuration window, click the Cancel button.

Related Topics
Drivehead Specification
Belts And Sheaves
Specification
Hydraulics
Prime Mover
Equipment Configuration
Analysis Inputs Overview
Printing Reports

You are here: Analysis Input Windows > Equipment Configuration > Surface Drive Equipment > Drivehead
Specification

Drivehead Specification
The drivehead information is specified under the Drivehead tab of the Surface
Drive Equipment Selection window. This window can be accessed by clicking
the Surface Drive Equipment update button
in the Equipment Configuration
window.

Surface Drive Equipment Selection - Drivehead Input Window

Intelligent Drive Selection

Users can select drive equipment based on recommendations from vendors by
selecting Intelligent drive selection active at the top of the Surface Drive Equipment
Selection window. When active, this option will:
Inform the user if the vendor has provided information about a drivehead
model to assist in selecting belts, hydraulics, sheaves and reduction ratios;
Indicate whether a particular drivehead is intended for use with belts
and/or hydraulics;
Indicate whether there are specific hydraulic motors which have been
identified by the drivehead vendor as compatible with their drivehead; and
Provide information about maximum/minimum sheave sizes and sheave
ratios.
If you wish to disable the warnings or select drive equipment that is not in the
recommended list for a particular drivehead, you can deactivate this feature by
deselecting Intelligent drive selection activeat the top of the Surface Drive
Equipment Selection window.

Specifying Drivehead Equipment Information

1. Select a vendor from the Company drop-down list.
2. Select a drivehead Model from the pull-down list available for that vendor.

3. Once a drivehead model is selected, the screen will be updated with the
following specifications.
Comments: Additional comments provided by the vendor.
Type: Vertical or right angle input shaft, internal bearing box or gear
box, and hollow or solid shaft.
Wellhead Connection:
Standard connection on the drivehead for
attachment to the wellhead.
Main Shaft Size: Standard main shaft size (polish rod size for hollow
shaft driveheads).
Maximum Main Shaft Torque: Maximum allowable torque that can be
handled by the main drive shaft.
Thrust Bearing Rating (ISO): Dynamic load rating (per ISO 281) for
the thrust bearing.
Maximum Structural Load: Maximum axial load that can be carried by
the drivehead frame.
Maximum Power:
Maximum power that can be handled by the
drivehead.
Maximum Speed (at Polish Rod): Maximum continuous rotational
speed of the polish rod.
Gearbox - Reduction: Gear reduction in the gearbox (greyed out if a
gearbox is not present).
Gearbox - AGMA Gear Torque: Maximum gear torque based on the
American Gear Manufacturers Association ratings (greyed out if a
gearbox is not present).
The key specifications to look at are the power rating, the torque rating
and the speed rating. There is also a structural load rating (which is not
available for all drives), a thrust bearing rating and a gear torque rating.
If you have selected a pump, and have an estimate of the operating speed
and differential pressure for the application, you can use the torque and
power graphs in PCPUMP's pump selection window to estimate how much
torque and power will be required. Alternatively, you can run the analysis
first without the surface equipment selected, and then select surface
equipment based on the results. Also look at the comments box or use the
Intelligent drive selection feature to ensure the drivehead is appropriate as
some driveheads are designed to operate with only hydraulic or only
electric motors.

Another thing to consider is the speed reduction within the drivehead.

Some driveheads have an internal gear box. This will affect the choices of
other equipment in the system, discussed below.
Note: When considering the thrust bearing rating, it is important to keep
the actual axial load in the system well below the thrust bearing rating. A
system operating right at its ISO thrust bearing rating will have a rated
life of only one million revolutions, which is only one month at 200 RPM.
PCPUMP will calculate an estimated bearing life based on the loading and
the rating. The estimated life is statistical90% of similar bearings will
last longer than the estimated time.

Once you have finished specifying the drivehead equipment information, select
another tab in the Surface Drive Equipment Selection window to continue
specifying surface drive equipment. Otherwise, click the OK button in the
bottom right-hand corner of the screen to confirm your inputs and return to
the Equipment Configuration window. To abort any changes and return to the
Equipment Configuration window, click the Cancel button.

Related Topics
Belts And Sheaves
Specification
Hydraulics
Prime Mover
Surface Drive
Equipment
Equipment
Configuration
Analysis Inputs
Overview
Printing Reports

You are here: Analysis Input Windows > Equipment Configuration > Surface Drive Equipment > Belts And
Sheaves Specification

Belts And Sheaves Specification

The surface drive belt information is specified using the Belts tab of the
Surface Drive Equipment Selection window. This window can be accessed by
clicking the Surface Drive Equipment update button
in the Equipment
Configuration window.

Surface Drive Equipment Specification - Belts Input Window

Because belts are an optional component, to configure them you must check
the Drive equipment includes belts box at the top of the screen.

Specifying Belt Equipment Information

1. Power Transmission Efficiency:
and sheaves system.

Power transmission efficiency of the belt

This value typically ranges between 90% and 98% for the V-belts
commonly employed in PC pumping systems.
2. Reduction Ratio: The total reduction ratio (ratio of the speed of the small
gear/sheave to the speed of the large gear/sheave) generated by the belt
and sheave system.
This can be entered directly if Specify Reduction is chosen, or it can be
calculated by entering the sizes of the small and large driver sheaves if
Calculate Reduction is chosen.
Issues to consider include minimum and maximum sheave sizes, belt
types, and belt tension and slippage.
Note: PCPUMP only takes into account manufacturer recommendations for
minimum/maximum sheave sizes when the minimum/maximum sheave
sizes have been provided by the manufacturer and Intelligent Drive
Selection is active.

Note: It is recommended that manufacturers' catalogues be consulted

when selecting belts for an installation.

Once you have finished specifying the belt equipment information, select
another tab in the Surface Drive Equipment Selection window to continue
specifying surface drive equipment. Otherwise, click the OK button in the
bottom right-hand corner of the screen to confirm your inputs and return to
the Equipment Configuration window. To abort any changes and return to the
Equipment Configuration window, click the Cancel button.

Related Topics
Drivehead Specification
Hydraulics
Prime Mover
Surface Drive Equipment
Equipment Configuration
Analysis Inputs Overview
Printing Reports

You are here: Analysis Input Windows > Equipment Configuration > Surface Drive Equipment > Hydraulics
Specification

Hydraulics
Hydraulics are sometimes incorporated in PC pumping systems to increase the
turndown ratio and allow variable speed control.
These systems consist of:
a hydraulic pump attached to the output shaft of the prime mover;
various intermediate valves and plumbing;
a fluid reservoir and filtration system; and,
a hydraulic motor attached to either a belt and sheaves assembly or the
drivehead input shaft.
The hydraulic information is specified using the Hydraulics tab of the Surface
Drive Equipment Selection window. This window can be accessed by clicking
the Surface Drive Equipment update button
in the Equipment Configuration
window.

Surface Drive Equipment Selection - Hydraulics Input Window

Hydraulics are considered an optional component of a surface drive system in

PCPUMP. To include them in a drive equipment configuration, you must check
the Drive equipment includes hydraulics box at the top of the screen.

Specifying Hydraulic Equipment Information

1. Select a hydraulic motor from the list of Models available.
2. Once a hydraulic motor is selected, the screen will be updated with the
following specifications.
Displacement: The volume of fluid required to produce one revolution
of the hydraulic motor.
Torque Output: The torque output of the hydraulic motor as a function

of operating pressure.
Maximum Pressure (peak) and Maximum Pressure (cont.):
The
maximum and continuous operating pressures of the hydraulic motor,
respectively.
Continuous Operating Speed (min.) and Continuous Operating Speed
(max.): The minimum and maximum continuous operating speeds of
the hydraulic motor, respectively.
3. Select a hydraulic pump from the list of Models available.
4. Once a hydraulic pump is selected, the screen will be updated with the
following specifications.
Full Displacement: The maximum volume of fluid that can be displaced
with each revolution of the hydraulic pump.
Maximum Pressure (peak) and Maximum Pressure (cont.):
The
maximum and continuous operating pressures of the hydraulic pump,
respectively.
Continuous Operating Speed (min.) and Continuous Operating Speed
(max.): The minimum and maximum continuous operating speeds of
the hydraulic pump, respectively.
Once you have finished specifying the hydraulic equipment information, select
another tab in the Surface Drive Equipment Selection window to continue
specifying surface drive equipment. Otherwise, click the OK button in the
bottom right-hand corner of the screen to confirm your inputs and return to
the Equipment Configuration window. To abort any changes and return to the
Equipment Configuration window, click the Cancel button.

Hydraulic Equipment Selection - Technical Discussion

The main point to consider when selecting hydraulics is the ratio of the
displacements of the hydraulic pump and motor, as this will affect the speed of
the downhole pump.
There are other issues as well, such as the pressure and speed ratings of the
hydraulic pump and motor; these do not often pose a problem in selecting
hydraulics, however, unless the displacements are greatly mismatched. The
following information is intended only to help with an initial selectionthe use
of PCPUMP is recommended to verify the calculations.

Hydraulic Power Motor

Assuming 100% mechanical efficiency in the drivehead (including gearbox,
if applicable) and the belt system, the power required from the hydraulic
motor is:
P = 1.047x104 x Tpr x Npr
Where:
P is power, kW
Tpr is the torque at the Polish Rod, Nm
Npr is the speed at the Polish Rod, RPM
With the assumption of 100% efficiency everywhere, this is the same as
the power at the electric motor.
When making a selection, hydraulic motors with a lower continuous power
rating than this can be eliminated from consideration. Also, since the
operating efficiencies of the hydraulic pump and motor are never 100%,
hydraulic motors with a continuous power rating that are at least 20%
greater than the calculated value may be most applicable.
Hydraulic Motor Speed
The speed of the hydraulic motor is:
Nhm = Npr x Rg x Rb
Where:
Nhm is the speed at the Hydraulic Motor, RPM
Npr is the speed at the Polish Rod, RPM
Rg is the gear reduction ratio
Rb is the belt reduction ratio
Any motors with a minimum speed greater than this can be eliminated
from consideration, as can any motors with a maximum speed less than
this.

Hydraulic Pump Speed

The hydraulic pump speed is the desired speed of the prime mover. You
will need an estimate of the speed range over which your prime mover can
run efficiently. Ensure the selected hydraulic pump has a minimum and
maximum speed which bracket the prime mover speed. Most electric
motors used in PC pump applications are 6 pole motors which run at 1140
- 1180 RPM at 60 Hz. Some may be 4 pole motors, which run at 1710 1760 RPM. While 2 pole motors (3420 - 3520 RPM) also exist, these are
less likely to be used as the prime mover in a PC pump system.
Internal combustion engines used in the oilfield are adjustable in speed,
but are not normally designed for continuous operation above 1800 RPM.
Hydraulic Pump and Motor Selection
The displacements of the selected hydraulic pump and motor should have
the following ratio.
Vhm/Vhp = Rh = Nhp/Nhm
Where:
Vhm is the displacement of Hydraulic Motor, cm/rev
Vhp is the displacement of Hydraulic Pump, cm/rev
Rh is the hydraulic displacement ratio
Nhp is the speed at the Hydraulic Pump, RPM
Nhm is the speed at the Hydraulic Motor, RPM
When selecting possible combinations, it is wise to consider pumps with
larger displacements than the desired ratio would indicate, for two
reasons. First, the actual volumetric efficiencies are not 100% since some
fluid slippage occurs in both the pump and motor, and a larger pump
displacement is needed to account for these losses. Second, in order to
provide speed control, a swash plate adjustment is used on the pump. The
swash plate adjustment can be used to reduce the displacement of the
pump below its maximum value. If the hydraulic pump is selected so that
it operates at its maximum displacement, it will not be possible later to
increase the speed of the downhole pump using the swash plate
adjustment.

Check Pressure in Hydraulic System

The pressure in the hydraulic system is determined by the torque at the
hydraulic motor, and by the displacement of the hydraulic motor.
The torque at the hydraulic motor is:
Thm = Tpr/(Rg x Rb)
Where:
Thm is the torque at the hydraulic motor, Nm
Tpr is the torque at the Polish Rod, Nm
Rg is the gear reduction ratio
Rb is the belt reduction ratio
The formula for the hydraulic pressure is:
ph = 6283.2 x Thm/Vhm
Where:
ph is the hydraulic pressure, kPa
Thm is the torque at the hydraulic motor, Nm
Vhm

is the displacement of Hydraulic Motor, cm/rev

The operating hydraulic pressure should not exceed the maximum

continuous pressure rating for either the pump or motor.

The selection of displacements of the pump and motor may be an iterative

process. Start with a pair with the desired displacement ratio. Determine the
system pressure. If this exceeds the rating of either component, try to find
another pair with smaller displacements but a similar ratio, or a pump and/or
motor with the same displacement but a higher pressure rating.
This simplified approach for initial hydraulic equipment selection does not
consider either the mechanical or volumetric efficiency of the pump or motor.
All efficiencies are assumed to be 100%. PCPUMP, on the other hand, will
estimate volumetric and mechanical efficiencies of both the hydraulic pump
and motor. It is further assumed that the polish rod torque and speed are
known. Likewise, it is assumed that the belt reduction ratio and drivehead

gear reduction ratio are known, if applicable.

Note that some hydraulic systems are designed to have no belts or gears in
the system; the hydraulic unit drives the polish rod directly. If such a
drivehead is selected, the corresponding motor should also be selected and no
belts should be specified.

Related Topics
Drivehead Specification
Belts And Sheaves
Specification
Prime Mover
Surface Drive Equipment
Equipment Configuration
Analysis Inputs Overview
Printing Reports

You are here: Analysis Input Windows > Equipment Configuration > Surface Drive Equipment > Prime
Mover Specification

Prime Mover
The prime mover provides the energy to drive the rod string and pump. The
amount of power required from the prime mover is dependent on the power
demand at the polish rod and the transmission efficiency of the drive
equipment.
The two types of prime movers used in PC pumping systems are electric
motors and internal combustion engines.
Electric motors are the most
common type of prime mover, being employed in over 90% of the
installations. These motors are usually of the three-phase, squirrel cage rotor,
induction type. Motor performance curves are normally available from the
motor manufacturers.
Note that these curves usually describe the
performance of the motor when operated at 60 Hz.
Currently, PCPUMP only supports electric motors as a prime mover. If you want
to use an internal combustion engine, you will need to adjust the inputs
accordingly. Please contact CFER for more information.
The prime mover information is specified using the Prime Mover tab of the
Surface Drive Equipment Selection window. This window can be accessed by
clicking the Surface Drive Equipment update button
in the Equipment
Configuration window.

Surface Drive Equipment - Prime Mover Input Window

Specifying Prime Mover Equipment Information

1. Motor Power Rating: Rated power output when operated at the rated
supply frequency and voltage conditions. Note that for calculation
purposes, the supply frequency and voltage is assumed to be equivalent to
the prime mover nameplate frequency and nameplate voltage,
respectively.
2. Motor Poles: Number of motor poles (two, four, six or eight).

Note: Most motors used in PC pump applications are 6 pole motors, which
have a synchronous speed of 1200 RPM at 60 Hz.
3. Motor Slip: The difference between the actual operating speed and the
motor's synchronous speed at the operating frequency. The accuracy of
this value determines the accuracy of the relationship between motor
speed and frequency.
Induction motors used in PC pumping applications typically have values of
slip less than or equal to 5% of the synchronous speed at rated load.
Note that PCPUMP will not adjust the amount of slip when it adjusts
frequency. If a large change in frequency is required, you may need to
manually re-enter a more accurate value.
4. The Motor Speed (at Supply Frequency) is automatically calculated from
the Motor Poles and Motor Slip information.
5. Motor Efficiency (Nominal): Nominal efficiency at full load under the rated
supply frequency and voltage conditions.
In the range of motor power ratings utilized in PC pumping applications,
nominal efficiencies typically range between 90% and 95%.
6. Motor Power Factor (Nominal): Nominal power factor (ratio of active to
apparent power) at full load under the rated supply frequency and voltage
conditions.
Nominal power factors typically range from 0.8 to 0.9 for induction motors
used in PC pumping applications.
Note: The motor performance can change significantly with the
frequency. You need to estimate the efficiencies, power factor and slop
values at the expected operating frequency, as PCPUMP does not contain
performance data for all the different motors available.
7. The Motor Full Load Current is automatically calculated from the Motor
Power Rating, Motor Efficiency, and Motor Power Factor information.

8. Supply Frequency: The frequency at which electrical power is supplied in

your area (typically 50 Hz or 60 Hz). For calculation purposes, the supply
frequency is assumed to be equivalent to the prime mover nameplate
frequency.
Note: This parameter is initially assigned a value based on the default set
in the Preferences window.
9. Supply Voltage: The voltage at which electrical power is supplied in your
area. For calculation purposes, the supply voltage is assumed to be
equivalent to the prime mover nameplate voltage.
Note: This parameter is initially assigned a value based on the default set
in the Preferences window.

10. Energy Cost: Average cost of electrical energy in $/kWh.

Note: This parameter is initially assigned a value based on the default set
in the Preferences window.

11. In certain cases, the drive equipment specifications must be adjusted to

match the pump speed (if specified in operating conditions). The Pump
Speed Matching options specify which way the pump speed is matched to
the drive equipment.
Match pump speed by adjusting prime mover speed:

The prime mover speed

will be adjusted to match the pump speed based on the reduction
ratios of the belts, gears and/or hydraulics.
Since PC-PUMP allows only for electric motors, this will be done by
modifying the operating frequency (to replicate a variable frequency
drive system).
Match pump speed by adjusting belt reduction ratio / hydraulic pump displacement:

The belt reduction ratio or hydraulics will be adjusted to match the

pump speed.
If there are no hydraulics, the belt reduction ratio will be adjusted (the
reduction ratio you specified will be overridden). However, if the drive
equipment contains hydraulics, they will be adjusted instead. (In

practice, this is done by altering the swash-plate on the hydraulic

pump to vary its displacement.)
Note: It is assumed that all the pumps in the database have
adjustable displacements; this should be verified for your selected
equipment.

Once you have finished specifying the prime mover equipment information,
select another tab in the Surface Drive Equipment Selection window to
continue specifying surface drive equipment. Otherwise, click the OK button in
the bottom right-hand corner of the screen to confirm your inputs and return
to the Equipment Configuration window. To abort any changes and return to
the Equipment Configuration window, click the Cancel button.

Related Topics
Drivehead Specification
Belts And Sheaves
Specification
Hydraulics
Surface Drive Equipment
Equipment Configuration
Analysis Inputs Overview
Printing Reports
Setting Program
Preferences

You are here: Analysis Input Windows > Equipment Configuration > Downhole Drive Equipment > Overview

Downhole Drive Equipment

In a downhole drive PC pumping system, the drive equipment consists of a
submersible electric motor, a drive assembly that connects the motor to the PC
pump, and the cable, which supplies the motor with electricity from surface.
To select downhole drive equipment, select the Equipment Configuration tab at
the top of the screen and select Downhole under the Drive Location section at
the top left corner of the window. The Downhole Drive Equipment Selection
window is accessed by clicking the Downhole Drive Equipment update button
in
the Equipment Configuration window.

Downhole Drive Equipment Selection Input Window

The tabs on the top of the Downhole Drive Equipment Selection window can
then be used to move between the following three major downhole drive
equipment components:
Drive Assembly;
Motor; and
Cable.
Once you have finalized selecting all the downhole drive equipment
components, click the OK button to return to the Equipment Configuration
window. A summary of the chosen drive equipment will be displayed in a list
box under the Downhole Drive Equipment update button.
To abort any changes made to the drive equipment configuration and return to
the Equipment Configuration window, click the Cancel button.

Related Topics
Drive Assembly
Specification
Analysis Inputs Overview
Analysis Inputs Overview

Analysis Inputs Overview

Analysis Inputs Overview
Printing Reports

You are here: Analysis Input Windows > Equipment Configuration > Downhole Drive Equipment > Drive
Assembly Specification

Drive Assembly Specification

The drive assembly is typically made up of a number of components and serves
to isolate the motor from the well fluids, react to the pump thrust load, provide
gear reduction between the motor and pump, and absorb the eccentric motion
of the pump rotor.
The drive assembly is specified using the Drive Assembly tab of the Downhole
Drive Equipment Selection window. This window can be accessed by clicking
the Downhole Drive Equipment update button
in the Equipment Configuration
window.

Downhole Drive Equipment Selection - Drive Assembly Input Window

Specifying Drive Assembly Equipment

1. Select a manufacturer from the Company drop-down list.
2. Select one of the manufacturer's drive assemblies from the Model dropdown list .
The drive assembly has similar ratings to the drivehead (torque, axial load,
speed). All drive assemblies have a gearbox, and this is the only speed
reduction available in DHD systems. In general, when selecting a DHD
motor and drive assembly, it is advisable to use the largest diameter which
will fit in the well with adequate clearance.
3. After a model is chosen, the screen will be updated with specifications for
the selected drive assembly.
Comments: Additional comments relating to this assembly, provided
by the manufacturer.
Type: The manufacturer's description of the type of drive assembly.
This will describe the different components in the assembly.

Outside Diameter:
The maximum outside diameter of the drive
assembly.
Length: The length of the drive assembly.
Pump Connection: The type of connection to the pump.
Power Requirement: The amount of power required to turn the drive
assembly when the system is in motion. This is the amount of power
lost between the motor output and the pump. Note that if this
information is not available from the manufacturer, a value of zero will
be displayed and used in the calculations.
Gear Reduction: The gearbox reduction within the drive assembly, if
any.
Maximum Torque: The maximum recommended operating torque on
the low speed side of the gear reduction.
Maximum Power: The maximum recommended output power of the
drive assembly.
Maximum Speed: The maximum recommended continuous running
speed of the drive assembly on the low speed side of the gear
reduction.
Maximum Thrust Load: The highest continuous operating axial load
that can be carried by the thrust bearings within the assembly.
Alternatively, you may click on the Create Custom button to enter the
specifications for a drive assembly which is not in the PCPUMP database.
For more information on creating a custom drive assembly, see the Custom
Drive Assembly Equipment page.
Once you have finished specifying the drive assembly, you can select any
of the other tabs in the Downhole Drive Equipment Selection window to
continue specifying the downhole drive equipment. Otherwise, click the OK
button in the bottom right-hand corner of the screen to confirm your
inputs and return to the Equipment Configuration window. To abort any
changes and return to the Equipment Configuration window, click the Cancel
button.

Related Topics
Custom Drive Assembly
Equipment
Analysis Inputs Overview

Analysis Inputs Overview

Analysis Inputs Overview
Analysis Inputs Overview
Analysis Inputs Overview
Printing Reports

You are here: Analysis Input Windows > Equipment Configuration > Downhole Drive Equipment > Custom
Drive Assembly

Custom Drive Assembly Equipment

You can create new drive assembly models that can be added to your own
custom databases. These drive assemblies can subsequently be selected and
used in the same manner as any of the assemblies included in the
manufacturers' equipment database.
You can add custom drive assemblies by clicking the Create Custom button in the
Drive Assembly tab of the Downhole Drive Equipment Selection window. This
window can be accessed by clicking the Downhole Drive Equipment update button
in the Equipment Configuration window.

Custom Drive Assembly Input Window

Specifying Custom Drive Assembly Information

1. On the left-side of the Custom Equipment window, you can select a custom
drive assembly file. Each file may contain one or more custom drive
assembly models. Once a file is selected, the names of these models will
appear under it. Highlighting a particular drive assembly model will
display the specifications of the selected model. If an existing drive
assembly model is selected to be edited, proceed to Step 4.
2. To create a new
will bring up a
Description and
created, you can
the OK button.

custom drive assembly file click the Add File button. This
window into which you must enter a Drive Assembly
a File Name. Although a file name is automatically
modify it within the lower edit box. When finished, click

New File: Custom Drive Assembly Window

3. Once a file has been created, new custom cable models can be created by
right-clicking on the file name and selecting the "Add Model" option.
Alternatively, you can duplicate an exiting model by selecting a Drive
Assembly model, right-clicking, and selecting "Duplicate Model". When you
have added a new model to the file, you can enter or update the model
specifications located on the right-side of the screen.

Custom Drive Assembly Model Input Window

4. The following specifications are required for custom drive assemblies:

Type: A description of the type of drive assembly. This should
describe the different components in the assembly.
Pump Connection: The type of connection to the pump.
Power Requirement: The amount of power required to turn the drive
assembly when the system is in motion. This is the amount of power
lost between the motor output and the pump. Note that if this
information is not available, a value of zero will be displayed and used
in the calculations.
Maximum Thrust Load: The highest continuous operating axial load
that can be carried by the thrust bearings within the assembly.
Maximum Speed: The maximum recommended continuous running
speed of the drive assembly on the low speed side of the gear
reduction.
Maximum Power: The maximum recommended output power of the
drive assembly.
Maximum Torque: The maximum recommended operating torque on
the low speed side of the gear reduction.
Length: The length of the drive assembly.
Gear Reduction: The gearbox reduction within the drive assembly, if
any.
Outside Diameter:
The maximum outside diameter of the drive
assembly.
Comments: Additional comments relating to this assembly.
It is important to ensure that the values you input correspond to the units
of measurement that are currently selected.

5. To remove a drive assembly from a database, select it by highlighting its

name, right-click and select "Delete Model".
Once you have finished, click OK to close the Custom Equipment input
window. All of the new custom drive assembly databases and their
corresponding models will now be available for selection and use throughout
PCPUMP.

Related Topics
Drive Assembly Specification
Analysis Inputs Overview
Analysis Inputs Overview
Analysis Inputs Overview
Printing Reports
Custom Equipment
Encryption

You are here: Analysis Input Windows > Equipment Configuration > Downhole Drive Equipment > Motor
Specification

Motor Specification
The motor is specified using the Motor tab of the Downhole Drive Equipment
Selection window. This window can be accessed by clicking the Downhole Drive
Equipment update button
in the Equipment Configuration window.

Downhole Drive Equipment Selection - Motor Input Window

Specifying Motor Equipment

1. Select a manufacturer from the Company drop-down list.
2. Select one of the manufacturer's motor models from the resulting Model
drop-down list.
3. After a model is chosen, the screen will be updated with specifications for
the selected motor.
Comments: Additional comments relating to this motor, provided by
the manufacturer.
Outside Diameter: The maximum outside diameter of the motor.
Length: The length of the motor.
Power Rating: The power rating of the motor when it operates at the
nameplate frequency and voltage.
Nameplate Voltage: The voltage at which the motor is designed to
operate.
Maximum Winding Temperature:
The maximum recommended
temperature that the motor windings can withstand in continuous
operation.
Note: A submersible electric motor can generate a significant quantity
of heat during operation. Please refer to the analysis options section
for more information on the effect of motor heating.

Number of Poles:
The number of electrical poles in the motor
(typically two, four or six).
Supply Frequency: The frequency at which electrical power is supplied
in your area. (This value is set in the PCPUMP defaults window.)
Synchronous speed at Supply Frequency: The speed at which the
motor will theoretically operate with no applied load, when the voltage
is applied at the supply frequency.
Nameplate Current: The current drawn by the motor when operating
at nameplate power, voltage and frequency.
Nameplate Frequency: The electrical frequency at which the motor is
designed to operate.
Energy Cost: The cost per kWh to run the motor. For additional
information, please refer to energy cost in defaults window.
Alternatively, you may click on the Create Custom button to enter the
specifications for a motor which is not in the PCPUMP database. For more
information on creating a custom motor, see the Custom Motor Equipment
Window page.
4. Downhole electrical motor performance is normally described by curves
(typically supplied by the motor's manufacturer). Speed, efficiency, power
factor and motor winding temperature curves are specified in relation to
the percent of rated power of the motor, as illustrated in the chart below.

Sample Downhole Motor Performance Curve

Downhole motor curves are generally only available at the motor

nameplate frequency and must be scaled appropriately when the motor is
to be operated at a different frequency. The following procedure is used by
PCPUMP:
1. The motor rated power and voltage are assumed to be proportional to
the operating frequency;
2. The motor load, in terms of percent of rated power, is calculated from
the computed motor shaft power and the scaled motor rated power;
3. Motor slip is calculated from the torque and frequency, or frequency is
calculated from the speed and torque;
4. The efficiency is calculated from the torque and frequency;
5. The power factor is calculated from the slip and frequency; and

6. The temperature rise is calculated from the power and efficiency.

It should be noted that these relations are only approximations of the
actual motor behavior. The motor manufacturer should be contacted in the
event that there is a large difference between the operating frequency and
the frequency for which motor information is available.
Under the Curves section of the window, you can specify the motor
operating performance in one of three ways. You have the option to Use
data from manufacturer which will use the manufacturer's motor performance
curves.
Another option is to Specify test data. To do this, click the Specify button,
which will take you to the Motor Test Information window. This window
allows you to enter motor performance curves that may be used when the
motor is selected for an analysis.
See the section on Motor Test
Information for step-by-step instructions on how to specify motor
performance curve data.
Choosing No curves (static) allows you to enter constant values for motor
operating parameters, regardless of the motor operating point. The values
which must be specified are:
Efficiency:
The efficiency at which the motor is assumed to be
operating, expressed as a percentage (0-100%). Note that electric
submersible motors typically have lower efficiencies than surface drive
motors.
Power Factor: The power factor at which the motor is assumed to
operate, expressed as a decimal fraction (0-1.00).
Slip: The difference between the actual operating speed and the
motor's synchronous speed at the operating frequency, expressed in
RPM.
Temperature Rise: The difference between the temperature of the
surface of the motor and the maximum temperature of the windings.
Many motors in the PCPUMP database have manufacturer-supplied
performance curves. When available, this is the recommended method of
modeling motor performance.
If you have chosen to use manufacturers' curves or a test to model motor
performance, you can view the curves on the right-hand side of the
window. User-specified motor test data can always be viewed in this way.
However, motor performance data may be considered by the manufacturer

to be proprietary and, while the relationships will be used to evaluate the

motor performance during analysis, the manufacturer's motor curves will
not always be accessible for graphical display. If you click on the Chart
drop-down list, you can switch between charts displaying Efficiency, Power
Factor, Speed and Temperature Rise.

Downhole Drive Equipment - Motor Chart Window

Once you have finished specifying the motor, you can select any of the
other tabs in the Downhole Drive Equipment Selection window to continue
specifying the downhole drive equipment. Otherwise, click the OK button in
the bottom right-hand corner of the screen to confirm your inputs and
return to the Equipment Configuration window. To abort any changes and
return to the Equipment Configuration window, click the Cancel button.

Related Topics
Analysis Inputs Overview
Analysis Inputs Overview
Drive Assembly Specification
Analysis Inputs Overview
Analysis Inputs Overview
Analysis Inputs Overview
Analysis Inputs Overview
Printing Reports

You are here: Analysis Input Windows > Equipment Configuration > Downhole Drive Equipment > Motor
Test Information

Motor Test Information

Within the Motor Test Information window, you can input, process, view and
save motor test information.
To access the Motor Test input window, select the Equipment Configuration tab,
then click on the Downhole Drive Equipment update button
. Within the Motor
tab of the Downhole Drive Equipment Selection window, select Specify test data
and click the Specify button.

Motor Test Information Input Window

Specifying Motor Test Information

1. The top of the window displays the Motor Model that the test information is
for.
2. The Motor Test Name drop-down list will display all pump tests associated
with the selected motor model. If an existing motor test is selected to be
edited, proceed to Step 4.
3. To create a new motor test, click the Create File button. This will bring up a
dialog box into which you must enter a Motor Test Name and a File Name.
Although a file name is automatically created, you can modify it within the
lower edit box. When finished, click the OK button and you will be
returned to the Motor Test Information input window along with a blank
pump test table.

4. To enter motor test data, enter the Motor Load (as a percentage of rated
load), Efficiency, Power Factor, Motor Speed and Temperature Rise
information for each test point. You can remove data from the table by

selecting the cell, right-clicking, and selecting "Delete Row(s)". To clear the
entire table, right-click, and select "Clear All Rows". Note that the data
points are automatically sorted by increasing motor load. The power supply
frequency at which the test was done must be entered in the Test
Frequency box below the table. This should be as close as possible to the
frequency at which the motor will be operated.
5. You can also examine motor test information graphically by selecting the
Chart tab. This will result in the data portion of the window being replaced
by a chart area as illustrated below. Using the Chart drop-down list, you
can display the following charts:
Motor
Motor
Motor
Motor

Load
Load
Load
Load

vs.
vs.
vs.
vs.

Efficiency
Power Factor
Motor Speed
Temperature Rise

PCPUMP fits a curve through the specified data points for use in the
primary calculation routines.
Because of the complexity of motor
performance curves and the variability in motor performance
characteristics, it is recommended that you check that the curves
generated from the motor test data are accurate before using them in an
actual analysis.

Once you have finished, click OK to close the Motor Test Information input
window. All inputs are automatically saved.

Related Topics
Motor Specification
Analysis Inputs Overview
Analysis Inputs Overview
Analysis Inputs Overview
Analysis Inputs Overview
Using Tables and Charts

Printing Reports

You are here: Analysis Input Windows > Equipment Configuration > Downhole Drive Equipment > Custom
Motor

Custom Motor Equipment Window

You can create new motor models that can be added to your own custom
databases. These motors can subsequently be selected and used in the same
manner as any of the motors included in the manufacturers' equipment
database.
You can add custom motors by clicking the Create Custom button in the Motor tab
of the Downhole Drive Equipment Selection window. This window can be
accessed by clicking the Downhole Drive Equipment update button
in the
Equipment Configuration window.

Custom Motor Input Window

Specifying Custom Motor Information

1. On the left-side of the Custom Equipment window, you can select a custom
motor database. Each database may contain one or more custom motor
models. Once a database is selected, the names of these models will
appear under it. Highlighting a particular motor model will display the
specifications of the selected model. If an existing motor model is selected
to be edited, proceed to Step 4.
2. To create a new custom motor file click the Add File button. This will bring
up a window into which you must enter a Motor Description and a File
Name. Although a file name is automatically created, you can modify it
within the lower edit box. When finished, click the OK button.

New File: Custom Motor Window

3. Once a file has been created, new custom cable models can be created by

right-clicking on the file name and selecting the "Add Model" option.
Alternatively, you can duplicate an exiting model by selecting a Motor
model, right-clicking, and selecting "Duplicate Model". When you have
added a new model to the file, you can enter or update the model
specifications located on the right-side of the screen.

Custom Motor Model Input Window

4. The following specifications are required for custom motors:

Outside Diameter: The maximum outside diameter of the motor.
Length: The overall length of the motor.
Number of poles:
The number of electrical poles in the motor,
normally two, four or six.
Power Rating: The full-load shaft power the motor produces at the
nameplate frequency.
Maximum Winding Temp.: The maximum recommended temperature
of the motor's windings.
Nameplate Frequency: The design frequency of the motor.
Nameplate Voltage: The design operating voltage of the motor at the
nameplate frequency.
Nameplate Current: The current the motor will draw when operating
at nameplate frequency and rated power.
Comments: Any additional comments about the custom motor.
It is important to ensure that the values you input correspond to the units
of measurement that are currently selected.
5. To remove a motor from a database, select it by highlighting its name,
right-click and select "Delete Model".
If performance curves are available for the custom motor, click on the Specify
button under Motor Performance in the bottom of the window. This opens the
Motor Test Information window, which allows you to enter motor performance
curves that may be used when the custom motor is selected for an analysis.
See the section on Motor Test Information for step-by-step instructions on
how to specify motor performance curve data.
Once you have finished, click

OK

to close the Custom Equipment input

window. All of the new custom motor databases and their corresponding
models will now be available for selection and use throughout PCPUMP.

Related Topics
Motor Specification
Analysis Inputs Overview
Analysis Inputs Overview
Analysis Inputs Overview
Analysis Inputs Overview
Using Tables and Charts
Printing Reports
Custom Equipment
Encryption

You are here: Analysis Input Windows > Equipment Configuration > Downhole Drive Equipment > Cable
Specification

Cable Specification
In downhole drive applications, it is important to monitor the voltage drop
through the cable and the cable conductor temperature. An excessive voltage
drop through the cable not only affects negatively the overall system
efficiency, but can also cause motor start-up problems. Power cable insulation
materials have temperature limits, and the conductor temperature must be
maintained below the limits specified by the manufacturer to avoid failures.
The power transmission cable is specified using the Cable tab of the Downhole
Drive Equipment Selection window. This window can be accessed by clicking
the Downhole Drive Equipment update button
in the Equipment Configuration
window.

Downhole Drive Equipment Selection - Cable Input Window

Specifying Cable Equipment

1. Select a manufacturer from the Company drop-down list.
2. Select one of the manufacturer's cable models from the resulting Model
drop-down list.
3. After a model is chosen, the screen will be updated with specifications for
the selected cable.
Comments: Additional comments related to this cable, provided by the
manufacturer.
Type: Flat or round cable. Flat cables have a lower thickness for the
same wire gauge.
Conductor Size: The American Wire Gauge (AWG) of the cable.
Note: The gauge (AWG) is 1, 2, 4, or 6 for most cables in the PCPUMP
database. The larger the number, the smaller the cable, and therefore
the less current capacity it will have.
Voltage ratings are not

considered in PCPUMP, because these cables are generally designed to

work with the motors used downhole.
Note:
If the voltage losses calculated by PCPUMP are high, then a
larger size of cable (smaller AWG) should be selected. The only
disadvantages of selecting a cable that is too large are cost and the
possibility that it won't fit in the well.
Maximum Conductor Temperature:
The maximum
temperature recommended by the manufacturer.

conductor

Overall Thickness: The cable thickness in the direction of the tubing

radius when banded to the tubing. This cable dimension is used to
verify consistency with the casing drift diameter to avoid problems
during installation of the downhole drive system.
Note: Cables are normally secured to the tubing string using bands.
The thickness of the bands is not considered in any of the calculations
in PCPUMP, but may be an issue in some cases, if there are very tight
clearances.
Appropriately sized motor lead used:

Check this box to have the software

check the clearance only above the pump, assuming that an
appropriately-sized motor lead is being used past the pump and drive
assembly to reach the motor.
Alternatively, you may click on the Create Custom button to enter the
specifications for a cable which is not in the PCPUMP database. For more
information on creating a custom cable, see the Custom Cable
Equipment page.
4. The chart in the window displays either a resistance chart (Cable Losses at
Conductor Temperature) or a conductor temperature chart (Conductor
Temperature at Ambient Temperature). Switching between charts is done
using the Chart drop-down list.
Once you have finished specifying the cable, you can select any of the
other tabs in the Downhole Drive Equipment Selection window to continue
specifying the downhole drive equipment. Otherwise, click the OK button in

the bottom right-hand corner of the screen to confirm your inputs and
return to the Equipment Configuration window. To abort any changes and
return to the Equipment Configuration window, click the Cancel button.

Related Topics
Analysis Inputs Overview
Drive Assembly
SpecificationAnalysis Inputs
Overview
Motor Specification
Analysis Inputs Overview
Analysis Inputs Overview
Using Tables and Charts
Analysis Inputs Overview
Printing Reports

You are here: Analysis Input Windows > Equipment Configuration > Downhole Drive Equipment > Custom
Cable

Custom Cable Equipment

You can create new cable models that can be added to your own custom
databases. These cables can subsequently be selected and used in the same
manner as any of the cables included in the manufacturers' equipment
database.
You can add custom cables by clicking the Create Custom button in the Cable tab
of the Downhole Drive Equipment Selection window. This window can be
accessed by clicking the Downhole Drive Equipment update button
in the
Equipment Configuration window.

Custom Cable Input Window

Specifying Custom Cable Information

1. On the left-side of the Custom Equipment window, you can select a custom
cable database. Each database may contain one or more custom cable
models. Once a database is selected, the names of these models will
appear under it. Highlighting a particular cable model will display the
specifications of the selected model. If an existing cable model is selected
to be edited, proceed to Step 4.
2. To create a new custom cable file click the Add File button. This will bring up
a window into which you must enter a Cable Description and a File Name.
Although a file name is automatically created, you can modify it within the
lower edit box. When finished, click the OK button.

New File: Custom Cable Window

3. Once a file has been created, new custom cable models can be created by

right-clicking on the file name and selecting the "Add Model" option.
Alternatively, you can duplicate an exiting model by selecting a Cable
model, right-clicking, and selecting "Duplicate Model". When you have
added a new model to the file, you can enter or update the model
specifications located on the right-side of the screen.

Custom Cable Model Input Window

4. The following specifications are required for custom cables:

Size: The cable's AWG gauge (1, 2, 4, 6, 8).
Thickness: This cable dimension is used to verify consistency with the
casing drift diameter to avoid problems during installation of the
downhole drive system.
Maximum Conductor Temperature: The maximum temperature for the
conductor recommended by the manufacturer.
Type: Flat or round.
Comments: Any additional comments about the cable.
It is important to ensure that the values you input correspond to the units
of measurement that are currently selected.
5. Ampacity curve information describes the cable's power transmission
performance.
The left hand section is used to describe the cable voltage drop as a
function of line current.
Enter the reference temperature in the Reference Temperature
edit box.
Enter the Current and associated Voltage Drop data in the
appropriate columns in the spreadsheet.
Note: PCPUMP will perform a linear regression on the data you
provide to model the voltage drop relationship, and will force the
curve fit to result in a voltage drop of zero if there is no current.
Specify as many data points as possible to make the cable

performance relationship more accurate.

The right-hand section is used to describe the heating performance of

the cable.
Enter the Conductor Temperature corresponding to the given
Current and Ambient Temperature in the spreadsheet. Specify as
many data points as possible to make the cable conductor
temperature relationship more accurate.

6. To remove a cable from the database, select it by highlighting its name,

right-click and select "Delete Model".

Once you have finished, click OK to close the Custom Equipment input
window. All of the new custom cable databases and their corresponding
models will now be available for selection and use throughout PCPUMP.

Related Topics
Cable Specification
Analysis Inputs Overview
Analysis Inputs Overview
Analysis Inputs Overview
Using Tables and Charts
Printing Reports
Custom Equipment Encryption

You are here: Analysis Input Windows > Equipment Configuration > DatabaseViewer

Database Viewer
The Database Viewer window allows users to quickly see what equipment is
available in the PCPUMP database. This window is accessed by clicking the Tools
menu option and selecting "Database Viewer". Certain parameters, which may
be confidential, are not displayed.

Database Viewer Window

Filter and Sorting

A filter is provided for quick investigations of available data. Select a
parameter and the bounds to show only those values of interest. To apply a
second filter, simply select a second parameter from the list and repeat the
process. This can be repeated until all parameters have a filter. The rows can
be sorted by clicking on the column header.

Related Topics
Equipment Configuration
Analysis Inputs Overview
Printing Reports

You are here: Analysis Input Windows > Fluid Properties > Overview

Fluid Properties
Fluid flow considerations are fundamental in the determination of pressure
gradients in the production tubing and tubing/casing annulus of an oil well.
These pressure profiles affect the lift requirement and thus impact any
production equipment which may be employed.
Pressure gradients are made up of three components.
Hydrostatic head or elevation, represents the weight of the fluid column
and is related to fluid density and vertical depth. The hydrostatic head is
normally the predominant component and contributes from 70 to 95% of
the total pressure in most oil wells.
Frictional losses is the result of pressure losses during fluid flow. These
losses occur along the length of the wellbore and are strongly dependent
on fluid viscosity and the flow geometry. Frictional losses typically account
for 5 to 25% of the total pressure gradient.
Acceleration or kinetic energy, occurs due to changes in fluid velocity. It is
normally negligible, and becomes significant only if a compressible phase
exists at relatively low pressures. At this time, PC-PUMP does not consider
this component when calculating pressure gradients.
Wellbore flow can be divided into several categories, depending on the flow
geometry, fluid properties and flow rate.
First, the flow in a wellbore can be classified as either single-phase or
multiphase. In most wells the flow is multiphase, with at least two phases
(e.g. gas and liquid) present. However, some wells either contain only a
single-phase or can be suitably modelled using single-phase algorithms.
Several flow geometries are also possible. In a rod-driven PC pumping
system, annular flow between the tubing and rod string as well as in the
tubing and casing annulus is most common. However, basic pipe flow
occurs through any tail joints and within the tubing in rod-less systems.
The properties of the fluids, both their PVT (pressure, volume,
temperature) behavior and their rheological characteristics, are also
important when assessing fluid flow.
Finally, depending on the flow rate and the fluid properties, flow in a
wellbore may be either laminar or turbulent, and this will greatly affect the
flow behavior.
PCPUMP has the ability to simulate either single-phase or multiphase fluid
flow. In a particular assessment, the type of flow modelled is determined by

the corresponding fluid properties mode that you select. In general, if there is
a significant, measurable quantity of gas, it is advisable to use the multiphase
mode.

Related Topics
Single-Phase Fluid Properties
Multiphase Fluid Properties
Advanced Fluid Viscosity
Fluid Thermal Properties
Diluent Injection Fluid Properties
Analysis Inputs Overview

You are here: Analysis Input Windows > Fluid Properties > Single-Phase Fluids

Single-Phase Fluid Properties

The single-phase fluid properties information is specified using the General
Properties tab in the Fluid Properties window. Ensure that Single-Phase is
selected at the top of the window.

Single-Phase Fluid General Properties Input Window

Specifying Single-Phase Fluid Composition Information

Water Cut: The water volume percentage derived from a BS&W (basic
sediment and water) analysis. Note that if a sand cut is specified, the
water cut is not necessarily equal to the percentage of the liquid portion of
the produced fluids that is water. For more details on how PCPUMP uses
the water cut, see the section on Single-Phase Fluid Flow - Technical
Considerations.
Sand Cut: The sand volume percentage derived from a BS&W (basic
sediment and water) analysis. For more details on how PCPUMP uses the
sand cut, see the section on Single-Phase Fluid Flow - Technical
Considerations.
Gas Specific Gravity:

Specific gravity of produced gas relative to air at

standard conditions.
Note: This parameter is initially assigned a value based on the default set
in the Preferences window (see the Setting Program Preferences section).

Specifying Single-Phase Fluid Density Information

The Fluid Density in the casing and tubing can be entered directly or calculated
using fluid properties.

If Specify
required:

Fluid Density

is selected, the following additional inputs are

Fluid Density - Tubing: The absolute density of the fluid in the tubing,
taking into account water, solids and gas content.
Fluid Density - Casing: The absolute density of the fluid in the casing,
taking into account water, solids and gas content.
If Calculate
required:

Fluid Density

is selected, the following additional inputs are

Oil API Gravity: The API gravity of the produced oil (after being
separated from water, gas and solids content).
Water Specific Gravity: Specific gravity of the produced water relative
to pure water at standard conditions. Due to salt content, produced
water often has a specific gravity slightly greater than 1.0.
Note: This parameter is initially assigned a value based on the default
set in the Preferences window (see the Setting Program Preferences
section).
Sand Specific Gravity: Specific gravity of the produced sand grains
relative to pure water at standard conditions. This is based on the
density of solid sand.
Note: This parameter is initially assigned a value based on the default
set in the Preferences window (see the Setting Program Preferences
section).
Tubing Density Factor: A factor which is multiplied by the calculated
composite density to arrive at a density of fluid in the tubing. (For
example, to account for gas, a factor less than 1.0 could be used; if no
correction needs to be made, use 1.0.)
Casing Density Factor: A factor which is multiplied by the calculated
composite density to arrive at a density of fluid in the casing.

Fluid Density - Tubing: This value is calculated based on the above

values and is the composite density of the fluid in the tubing.
Fluid Density - Casing: This value is calculated based on the above
values and is the composite density of the fluid in the casing.

Specifying Single-Phase Fluid Viscosity Information

Two options are available for entering information on the absolute (or
dynamic) fluid viscosity (in centipoises):

Selecting Specify Total Fluid Viscosity allows the user to enter the overall
mixture viscosity as single value.
Selecting Use Advanced Viscosity allows the user to enter relationships
between viscosity and temperature, shear rate, and/or BS&W (water and
sand). PCPUMP then uses this information to calculate a dynamic viscosity
at different points in the wellbore.
Note: See the Advanced Fluid Viscosity section for more information on
entering advanced viscosity information.

Related Topics
Single-Phase Fluid Flow - Technical
Considerations
Single-Phase Fluid Flow - Technical
Considerations
Multiphase Fluid Properties
Advanced Fluid Viscosity
Analysis Inputs Overview
Printing Reports

You are here: Analysis Input Windows > Fluid Properties > Single-Phase Fluid Flow - Technical
Considerations

Single-Phase Fluid Flow - Technical

Considerations
In single-phase flow, the fluids are assumed to be homogeneous and are
treated as being incompressible. The hydrostatic head is calculated based on
the average fluid density and the elevation (i.e. vertical depth) change.
PCPUMP allows separate densities to be input for the tubing and for the casing
(i.e. the tubing/casing annulus). The tubing density is used in the calculation
of the dynamic pressure gradients from the perforations to the pump and
throughout the tubing. The casing density is used in the calculation of the
static pressure gradient in the tubing/casing annulus below the fluid level.
For single-phase flow, the algorithms used in PCPUMP to determine the
frictional loss component of the dynamic pressure gradient are dependent on
flow rate, fluid properties and flow geometry. Either a laminar or turbulent
flow regime can exist depending on the flow rate and the fluid properties. On
the basis of their rheological properties, fluids are treated as either Newtonian
or non-Newtonian types18. Finally, the three types of flow geometry dealt with
are pipe flow, annular flow and eccentric annular flow.
Differentiation between the laminar and turbulent flow regimes is usually done
on the basis of the Reynolds number. In its simplest form, this parameter is
calculated based on the fluid density, flow velocity, pipe diameter and fluid
viscosity. However, annular flow and non-Newtonian fluids necessitate special
consideration for flow geometry and additional fluid properties, respectively.
Calculation of frictional losses requires the determination of friction factor
values. For laminar flow, PCPUMP uses the analytically derived Darcy friction
factor18 which can be calculated based only on the Reynolds number. In the
case of turbulent flow, the results of extensive experimental studies are
typically used.
PCPUMP uses the Zigrang and Sylvester14 explicit
approximation to the Colebrook equation to calculate turbulent friction factors.
This correlation requires the pipe roughness, pipe diameter and Reynolds
number.
Much of the published literature on single-phase fluid flow pertains specifically
to Newtonian fluids. This implies that the applied shear stress is proportional
to the shear strain rate and viscosity is the constant of proportionality (i.e.

shear stress = viscosity x shear rate).

However, many of the fluids
encountered in the petroleum industry do not exhibit Newtonian behavior.
Several fluid models are shown below which characterize the rheological
behavior of various viscous materials. The resistance to flow of a dilatant
(shear-thickening) fluid increases with increasing strain rate (i.e. viscosity
increases with increasing shear rate).
In contrast, the resistance of a
pseudoplastic (shear-thinning) fluid decreases with increasing strain rate (i.e.
viscosity decreases with increasing shear rate).

Types of Fluid Models

Most higher viscosity petroleum fluids (>100 cp) tend to be non-Newtonian

exhibiting pseudoplastic (shear-thinning) behavior. Two different methods can
be used to calculate frictional losses for non-Newtonian fluids. The first is to
substitute an apparent viscosity into the conventional Newtonian pressure loss
correlations. The second method, which is the one used in PCPUMP, is to first
fit the fluid properties to a power-law fluid model and then use the Metzner
and Reed15 generalized approach for calculating pressure losses.
The power-law fluid model has a consistency parameter, K, which is related to
the overall viscosity and a flow index, n, which quantifies the non-Newtonian
behavior. When n equals one, the fluid behaves as a Newtonian fluid. Values
of n less than one indicate a pseudoplastic fluid. Metzner and Reed formulated
a "generalized" Reynolds number for non-Newtonian flow. In the case of
laminar flow, this "generalized" Reynolds number is used in a similar fashion to
the conventional Reynolds number in determining a friction factor and
pressure loss. For turbulent flow, the "generalized" Reynolds number is
substituted into an implicit smooth pipe friction factor equation proposed by
Dodge and Metzner16. To adjust this smooth pipe friction factor to represent
flow in real pipes, it is multiplied by the ratio of the rough to smooth Fanning
friction factors (calculated at the same "generalized" Reynolds number) as
suggested by Govier and Aziz17.
With annular flow, the presence of an inner cylinder produces increased
frictional losses relative to standard pipe flow. Equations which describe
concentric annular fluid flow can be derived analytically18.
From these
equations, an effective flow diameter correlation can be determined.
Diameters calculated from this correlation can be substituted into the
conventional or "generalized" Reynolds numbers which in turn can be used in
the appropriate friction factor and pressure loss correlations.

To address eccentric fluid flow, PCPUMP multiplies the annular pressure losses
calculated above by factors determined based on correlations developed by
Haciislamoglu and Cartalos19. These correlations use the outside rod diameter,
inside tubing diameter and degree of eccentricity as inputs. Different versions
of the correlation are used for Newtonian and non-Newtonian fluids. Frictional
pressure losses in a fully eccentric geometry are approximately 50% of the
annular value. Reductions in pressure losses with increasing eccentricity are
due to the presence of a larger unrestricted flow area and its lower associated
fluid shear rates and stresses.
It is important to understand the approach taken in PCPUMP to account for
water and solids in produced fluids. The impact of sand and water content on
tubing and casing fluid density can be easily modelled using the fluid
composition option in single-phase flow, in which the sand and water cuts and
associated specific gravities are specified and the densities are calculated. In
this case, the program assumes that the specified sand specific gravity is for
dry sand grains, that the porosity of the sand is 40%, and that all porous
volume within the sand is occupied by water.
For all single-phase flow calculations, the produced fluid is considered to
consist of two components: oil, and basic sediment and water (BS&W). The
BS&W content is defined as the sum of the sand and water cuts from a
standard basic sediment and water analysis. When the specified sand cut is
non-zero, the composite IPR (water content adjustment with producing
pressure) and the advanced viscosity feature (fluid viscosity adjustment with
water content) use the BS&W content as the water phase volume
percentage. Caution should therefore be used when performing calculations
and interpreting results for applications with high sand cuts (>10%).
Warning: In downhole drive configurations, a combination of small clearances
(between casing or shroud and motor), high flow rates, and high viscosities
may generate significant frictional pressure losses between the perforations
and pump intake. PCPUMP will give an error message if these pressure losses
result in a calculated negative pump intake pressure.

Related Topics
Appendix A: References
Single-Phase Fluid
Properties
Fluid Properties

Analysis Inputs Overview

You are here: Analysis Input Windows > Fluid Properties > Multi-Phase Fluids

Multiphase Fluid Properties

The multiphase fluid properties information is specified using the General
Properties tab of the Fluid Properties window. Ensure that Multiphase is selected
at the top of the tab window.

Multiphase Fluid General Properties Input Window

Specifying Multiphase Fluid Information

Oil API Gravity: API gravity of the produced oil.
Water Salinity:
Specific gravity (relative to pure water at standard
conditions) of the produced water. Due to salt content, produced water
often has a specific gravity slightly greater than 1.0.
Note: This parameter is initially assigned a value based on the default set
in the Preferences window (see the Setting Program Preferences section).
BS&W Content: The percentage of the produced fluid that is water and
sand. If you have specified a composite IPR, this value will be calculated
and the input box will be greyed-out.
Gas Specific Gravity:
Specific gravity (relative to air at standard
conditions) of the produced gas.
Note: This parameter is initially assigned a value based on the default set
in the Preferences window (see the Setting Program Preferences section).
You can select to enter either the

Producing GOR

or the

Producing GLR.

Producing GOR: The producing gas/oil ratio, measured at standard

conditions (15C and atmospheric pressure). This must consider the

total quantity of gas produced up the casing and tubing.

Producing GLR: The producing gas/liquid ratio, measured at standard
conditions (15C and atmospheric pressure). This must consider the
total quantity of gas produced up the casing and tubing. This
parameter is used when there is no oil, for example in the dewatering
of gas or coal bed methane wells.

Free Gas Separation is the percentage of free gas at either the pump or
tail joint intake which is separated and diverted up the casing/tubing
annulus. This value is used to determine the annular and tubing gas
rates.
Note: This parameter is initially assigned a value based on the default set
in the Preferences window (see the Setting Program Preferences section).
You can select to either

Specify Free Gas Separation to Annulus

Calculate Free Gas Separation to Annulus

or have PCPUMP

for you.

More information on how PC-PUMP handles free gas separation can be found
in the Multiphase Fluid Flow - Technical Considerations section.

Specifying Multiphase Fluid Viscosity Information

Two options are available for entering information on the absolute (or
dynamic) fluid viscosity (in centipoises):

Selecting Calculate
fluid viscosity.

Total Fluid Viscosity

lets the software calculate the overall

Selecting Use Advanced Viscosity when Multiphase is selected allows the user
to enter relationships between viscosity and temperature. PCPUMP then
uses this information to calculate a dynamic viscosity at different points in
the wellbore.
Note: See the Advanced Fluid Viscosity section for more information on
entering advanced viscosity information.

Related Topics
Multiphase Correlations
Multiphase Correlations
Multiphase Fluid Flow - Technical
Considerations
Single-Phase Fluid Properties
Advanced Fluid Viscosity
Analysis Inputs Overview
Printing Reports

You are here: Analysis Input Windows > Fluid Properties > Multi-Phase Correlations

Multiphase Correlations
In multiphase mode you have the option of selecting different correlations for
various fluid properties. More information on the correlations included in the
software can be found in the Multiphase Fluid Flow - Technical Considerations
section.
The multiphase correlations information is selected in the
Correlations tab in the Fluid Properties window. Ensure that
selected at the top of the window.

Multiphase
Multiphase is

Multiphase Correlations Input Window

Once an Oil API Gravity and Producing GOR

entered in the General Properties tab, the
correlation will be displayed on a graph to
appropriate correlation for a particular fluid.
follows:

or Producing GLR have been

results of each multiphase
assist in selecting the most
The results are displayed as

Solid Line With Points: Shows the results of the currently selected
correlation within the prescribed boundaries of the correlation (Oil API
gravity, temperature, pressure, GOR/GLR, and gas specific gravity)
Solid Line Without Points: Shows the results of the all correlations
other than the selected correlation within the prescribed boundaries of the
correlation (Oil API gravity, temperature, pressure, GOR/GLR, and gas
specific gravity)
Dotted Line With Points: Shows the results of the currently selected
correlation extrapolated beyond the prescribed boundaries of the
correlation (Oil API gravity, temperature, pressure, GOR/GLR, and gas
specific gravity)
Dotted Line Without Points: Shows the results of the all correlations
other than the selected correlation extrapolated beyond the prescribed
boundaries of the correlation (Oil API gravity, temperature, pressure,
GOR/GLR, and gas specific gravity)
For correlations that vary with pressure, the results can be viewed over a
range of different pressures by entering a Minimum Pressure, Maximum

Pressure and Pressure Increment and then using the slider located below the
graph.
You can revert to the default correlations by clicking on the
in this window.

Load Defaults

button

These correlations can also be specified in the Preferences window (see the
Setting Program Preferences section). Changing the correlations in this
window, however, does not change the defaults, but only affects the current
case.

Related Topics
Multiphase Fluid Properties
Multiphase Fluid Flow - Technical
Considerations
Fluid Properties
Analysis Inputs Overview
Printing Reports

You are here: Analysis Input Windows > Fluid Properties > Multi-Phase Fluid Flow - Technical Considerations

Multiphase Fluid Flow - Technical Considerations

Multiphase flow can be defined as the simultaneous flow of two or more phases
(e.g. oil, gas, water, sand). In an oil well, whenever the pressure drops below
the bubble point, gas will evolve resulting in gas-liquid flow. As this gas-liquid
mixture flows through the production system, the two phases will distribute in
a variety of patterns. The particular pattern or "flow regime" which occurs has
a significant effect on multiphase flow behavior. Flow regime maps facilitate
the determination of flow patterns based on gas and liquid flow rates as well as
fluid properties. These inputs for the flow regime maps are obtained using
empirical fluid property correlations. Depending on the particular flow regime,
different multiphase flow algorithms are used for calculating the hydrostatic
and frictional pressure gradients. The hydrostatic gradient is determined using
both gas and liquid densities and takes into account a phenomenon known as
liquid holdup. The frictional gradient is calculated using friction factors based
on two-phase fluid properties57.
In multiphase flow, the amount of pipe occupied by a phase is often different
from its proportion of the total volumetric flow rate. Typically, in upward gas
liquid flow, the lighter gas phase moves faster than the denser liquid phase.
Because of this holdup phenomenon, the in-situ volume fraction of the liquid
phase will be greater than its input volume fraction. In other words, the liquid
is "held up" in the pipe relative to the gas. Liquid holdup is defined as the
ratio of the volume of a pipe segment occupied by liquid to the volume of the
pipe segment. Consequently, it is a fraction which varies from zero for all gas
flow to one for all liquid flow. A parameter commonly used in some multiphase
flow calculations is no-slip holdup. It is defined as the ratio of the liquid input
fraction to the total input fraction.
When determining the hydrostatic
gradient, it is important to use an accurate liquid holdup value, and not the
no-slip holdup.
The diagram below illustrates the procedure used in PCPUMP for multiphase
flow calculations. In the following sections, the fluid property correlations,
flow pattern mapping and multiphase flow algorithms used in the software will
be described in more detail.

PCPUMP Multiphase Flow Calculation Procedure

Fluid Property Correlations

Completion of a multiphase flow assessment requires the calculation of
numerous fluid properties. These properties, several of which include density,
viscosity and surface tension, are associated with the gas, water and oil
components. Many empirical correlations are available in the literature for
predicting each of these fluid properties. However, care must be taken to
ensure that the correlations are not extended beyond their range of validity.
For example, many correlations were based on data from medium to high API
oils, and may not be applicable to heavy oil. During the development of
PCPUMP, an extensive review and comparison of the publicly available
correlations was completed. Based on this work, the following correlations
were selected for PCPUMP on the basis of being the most appropriate for oil
well multiphase flow assessments.
Dissolved and Free Gas Specific Gravities - Katz et al.21
Oil Isothermal Compressibility - Vazquez & Beggs20
Oil Volume Factor - Vazquez & Beggs20
Water Isothermal Compressibility - Osif22
Water Volume Factor - Katz et al.21
Pseudo-reduced Temperature and Pressure - Sutton23
Gas Compressibility Factor - Dranchuk, Purvis & Robinson24
Gas/Oil Surface Tension - Baker & Swerdloff25
Gas/Water Surface Tension - Jennings26
Water Viscosity - McCain29
Gas Viscosity - Lee et al.30
In addition, other properties allow the user to choose which correlation to use:
Solution Gas/Oil Ratio
Vazquez & Beggs20,57,60
Glaso60
De Ghetto et al.62
Standing57,60
Bubble Point Pressure
De Ghetto et al.62
Standing (1)64
Standing (2)60

Glaso60
Vazquez & Beggs60
Dead Oil Viscosity
Glaso58,59
Ng & Egbogah27,64
De Ghetto et al.62
Beggs & Robinson28,59
C?FER/HOGS61
Kartoatmodjo58,63
Bennison58
Beal58
Egbogah & Jack58
Labedi58
Petrosky & Farshad58
Live Oil Viscosity
Beggs & Robinson28,57,59
Kartoatmodjo63
De Ghetto et al.62
Undersaturated Oil Viscosity
Vasquez & Beggs20,57,59,64
Kartoatmodjo63
De Ghetto et al.62
All fluid property correlations have been developed from databases of
laboratory fluid tests. Consequently, they have a valid range which is based
on the data from which the correlation was developed. To prevent using these
correlations outside of their appropriate ranges, PCPUMP imposes limits on
several of the multiphase fluid property input parameters. In particular, the
gas specific gravity must be between 0.55 and 1.2 and the fluid temperature
between 0C and 200C. Warnings are also issued for oil gravities less than
15API. The user-selectable correlations have different limits, which are given
below, and warning messages will be issued if these limits are exceeded at any
point in the well.
If a range of applicability is not given in the table below this simply means that
no range was described in the original source. It should not be assumed that
these correlations cover a large range.

Dead Oil Viscosity

Correlation

Range of Applicability

Glaso
Ng & Egobah

T: 15-80C (59-176F)
API: 5-58

De Ghetto et al.

T: 55.2-121.5C (131.4-250.7F)
API: 6-23

Beggs
Robinson

& T: 21.1-146.1C (70-295F)

API: 16-58

C?FER/HOGS

T: 20-70C (68-158F)
API: 9-13.3

Kartoatmodjo

T: 23.9-160C (75-320F)
API: 14.4-59

Bennison

T: 10-93.3C (50-200F)
API: 10-20

Beal
Egobah & Jack
T: 37.8-152.2C (100-306F)
API: 32.2-48

Labedi
Petrosky
Farshad

&

Live Oil Viscosity

Correlation
Beggs
Robinson

Range of Applicability
& R s:
3.56-368.7
scf/bbl)

m3/m3

(20-2070

Kartoatmodjo

Rs: 0-514.7 m3/m3 (0-2890 scf/bbl)

De Ghetto et al.

Rs: 3.07-114 m3/m3 (17.21-640.25

scf/bbl)
API: 6-23

Undersaturated Oil Viscosity

Correlation

Range of Applicability

Vasquez & Beggs

Kartoatmodjo

170.3-49440 kPaa (24.7-7170.7 psia)

P: 100-5186 kPaa (14.5-752.2 psia)

De Ghetto et al.

Pb: 1441-27731 kPaa (209-4022 psia)

mod: 7.7-1386.9 cp
API: 6-23

Solution GOR
Correlation

Range of Applicability

Vasquez & Beggs

Glaso

T: 10-148.9C (50-300F)
P: (58-6050 psia)
SGgas: 0.574 or higher
API: 17.9-51.1

De Ghetto et al.

T: 55.2-121.1C (131.4-250F)
API: 6-23
SGgas: 0.623-1.517

Standing

Bubble Point
Correlation

Range of Applicability

De Ghetto et al.

T: 55.2-121.1C (131.4-250F)
API: 10-22.2
GOR: 3.07-114 m3/m3 (17.21-640.2
scf/bbl)
SGgas: 0.623-1.517

Standing (1)
Standing (2)
Glaso

T: 10-148.9C (50-300F)
API: 17.9-51.1
SGgas: 0.574 or higher

Vasquez & Beggs

Where:
T is the fluid temperature RPM, C
API is the oil density, API
Rs is the solution Gas Oil Ratio
P is the mixture pressure, kPaa
Pb is the bubble point pressure, kPaa
mod is the mixture viscosity, cp

SGgas is the specific gravity of the gas

GOR is the gas oil ratio
Water and sand content in the produced fluid are lumped together as the
BS&W content (basic sediment and water) for multiphase flow. This value is
the sum of the sand and water cuts from a standard basic sediment and water
analysis. The BS&W Content variable is used in any flow calculations which
make use of the volume or mass percentage of water in the mixture.
Because the dead oil viscosity correlations may not be appropriate for all crude
oils, PCPUMP allows you to override the default dead oil viscosity correlation
with customized temperature-sensitive dead oil viscosity data using the
Advanced Viscosity feature. In this case, the live oil viscosity is still obtained
from the dead oil viscosity data by use of a correlation.
Flow Pattern Identification and Mapping
The manner in which the liquid and gas are distributed in the pipe has a
significant affect on the nature of the multiphase flow. The "flow regime" or
flow pattern is a qualitative description of the phase distribution. Flow pattern
maps can be formulated based primarily on liquid and gas superficial velocities
to allow the identification of different flow regimes. The flow pattern maps and
their associated patterns vary for upward vertical/inclined, downward
vertical/inclined and horizontal flow. In gas-liquid vertical/inclined upward
flow, four flow patterns are generally agreed upon: bubble, dispersed bubble,
slug and annular flow. A typical flow pattern map for this type of flow is shown
below.

Typical Flow Pattern Map

With bubble and dispersed bubble flow, the liquid phase is continuous and the
free gas phase is present only as relatively small bubbles. While the bubble
flow regime occurs at low liquid velocities (allowing the gas bubbles to move
faster than the liquid), the dispersed bubble regime is characterized by high
turbulence, and both phases move together as a homogeneous mixture. In
slug flow, although the liquid phase is still continuous, the gas coalesces to
form large bubbles which almost fill the pipe cross section. The gas bubble
velocity is greater than that of the liquid that moves in slugs between the long
gas bubbles. In annular flow, the gas phase is continuous and occupies the
center of the pipe. Some of the liquid is entrained as droplets in the gas
phase, and some coats the pipe wall as a liquid film.

Recently, physical models have been developed which allow the analytical
prediction of flow patterns and their associated transition boundaries for
steady state gas-liquid flow. Based on flow rates, fluid properties and flow
geometry, flow pattern maps can be generated. The basic work on pattern
transitions for upward two-phase flow was completed by Taitel et al.31. Later,
modifications to the transitions were made by Barnea et al.32,33 to extend the
applicability of the model to inclined flows. Results from these two works form
the basis for flow pattern identification within PCPUMP. The model which is
integrated into the software encompasses the four common flow patterns
defined above and exhibits smooth transitions through a wide range of pipe
inclinations.
Multiphase Flow Models
Numerous correlations and models have been developed for predicting
multiphase flow behavior in wells. However, they all share the common
primary objective of determining accurate hydrostatic and frictional pressure
gradients.
In accomplishing this, some models predict important flow
characteristics such as the liquid holdup.
The early multiphase flow models incorporated single-phase flow equations
with mixture variables and did not consider liquid holdup or address distinct
flow patterns. Examples of these homogenous models are Poettmann &
Carpenter34 and Fancher and Brown. Extensive experimentation resulted in
the development of generalized empirical correlations (e.g. Duns & Ros35,
Hagedorn & Brown36, Beggs & Brill37). These formulations incorporated liquid
holdup correlations and established basic flow patterns. Subsequently, simple
mechanistic models (e.g. Orkiszewski38, Aziz et al.39) began to consider the
fundamental flow mechanisms. Most recently, comprehensive mechanistic
models have been developed which incorporate elaborate flow pattern
prediction models and treat the physical flow mechanics rigorously. Their
scope also tends to be broader, including in some cases annular and inclined
flow. Hasan & Kabir40, Ansari et al.41 and the proprietary Shell models42
(MMSM & GZM) are examples of these comprehensive mechanistic models.
PCPUMP required a multiphase flow model with which to determine pressure
gradients and flow characteristics for fluid flowing through the production
tubing as well as the tail joints. A review of several comparative studies42,43
revealed that Ansari's comprehensive mechanistic model is one of the most
accurate models available (for upward flow) in the public domain.
Consequently, this model was selected to form the basis for the flow algorithms
included in PCPUMP.

Static Annular Pressure Gradient

In order to assess a well with two-phase gas-liquid flow, it is also necessary to
evaluate the static pressure gradient in the tubing/casing annulus. It is
essential that this gradient is calculated accurately since it determines the
pressure at the pump or tail joint intake which in turn affects the distribution
of gas flow up the annulus and production tubing. The gas flow up the annulus
is denoted by the casing gas rate and expressed in cubic meters per day at
standard conditions (i.e. 101.3 kPa and 15.6C). Gas flow up the production
tubing is characterized by the tubing gas/oil ratio (GOR) which refers to the
GOR when all of the gas in the tubing is in solution. The casing gas rate and
tubing GOR have significant effects on the pressure profiles within the
tubing/casing annulus and production tubing, respectively.
PCPUMP's pressure gradient calculations depend on the system configuration.
The diagram below illustrates how the relative locations of the production
string intake (i.e. tubing or tail joint) and perforations impact the two-phase
flow behavior.

Impact of Two-Phase Behaviour By System Configuration

The following two sub-sections describe the flow behavior for system
configurations with the perforations above and below the production string
intake. This includes the basic theory and assumptions used by PCPUMP is
completing the multiphase flow evaluations.
Perforations Above Production String Intake
Consider a configuration where the perforations are above the production
string intake. If the pressure at the perforations is equal to or above the
bubble point of the fluid, there will be no free gas present and the solution
GOR will be equal to the producing GOR. However, if the pressure at the
perforations is below the bubble point, there will be free gas at the
perforations and the solution GOR will be less than the producing GOR. By
default, PCPUMP assumes that, when the perforations are above the production
string intake, the free gas at the perforations is diverted up the annulus and
yields a casing gas rate. Note, however, that narrow annuli can create high
flow velocities that "pull" gas down into the intake along with the liquid
stream. PCPUMP therefore gives you the ability to override the assumption
that all the free gas at the perforations travels up the casing.

With the perforations above the production string intake, the pressure at the
string intake is usually higher than at the perforations. Consequently, the
solution GOR at the intake (i.e. the tubing GOR) is equal to that at the
perforations. In addition, since all of the free gas is assumed to have been
separated above at the lower pressure perforation location, there is no free
gas at the production string intake, unless this assumption is overridden by
the user. Note, however, that if the pumping system configuration includes a
tail joint (or a shroud around a downhole motor), the reduction in pressure
along its length can result in gas evolution and free gas being present at the
pump intake.
In calculating the annular pressure gradient, the starting point is the surface
casing head pressure. The gas gradient is calculated from surface down to the
gas/liquid interface (i.e. fluid level) based on standard gas compressibility
correlations23,24. Next, the gradient is determined for the liquid column. In
this configuration, where the perforations are above the production string
intake, it is assumed that the annular area above the perforations contains
only oil since its density is lower than that of water. However, this oil column
will be lightened by any gas venting up through the annulus. To address this
effect, Godbey and Dimon's mechanistic model44 is used to calculate the gas
void fractions based on the bubble rise velocity through the stagnant oil
column. Using the gas void fraction, fluid densities and pressure gradients are
determined which consider the upward gas flow. For the annular column
between the perforations and pump intake, the fluid composition (i.e. oil and
water) is assumed to be of the same ratio as the produced fluids. In this
interval, hydrostatic pressure gradients are determined based on the density
of a homogeneous gas-liquid mixture. Note that friction pressure losses in the
flowing region of the tubing/casing annulus are also considered.
Perforations Below Production String Intake
Next, consider the configuration where the perforations are below the
production string intake. If the pressure at the production string intake is
above the bubble point of the fluid, no free gas will evolve and the solution
GOR will be equal to the producing GOR. In this case, the tubing GOR will also
be equal to the producing GOR and the casing gas rate will be zero.
However, if the pressure at the intake is below the bubble point, free gas will
be present and the solution GOR will be lower than the producing GOR. Some
of this free gas will enter the production string, move upwards through the
pump and travel to surface via the tubing. PC pumps can handle free gas,
however, it results in reduced volumetric efficiencies and, in severe cases, may
cause permanent pump damage. Fortunately, through natural separation,

typically 30% to 60%45 of the free gas present at the production string intake
is diverted up the tubing/casing annulus. To further improve separation
efficiency, gas separators are sometimes installed.
When free gas is present at the production string intake, the tubing GOR may
be higher than the solution GOR at this location because a portion of the free
gas may enter the production string. The casing gas rate is comprised of any
free gas diverted up the annulus (see the above diagram).
Determination of the annular pressure gradient with the perforations below
the production string intake is similar to that described previously for
perforations above the intake. The gradient for the gas column is calculated in
an identical fashion. Next, the oil column from the gas/liquid interface down
to the production string intake is determined in the same way as the oil
column from the gas/liquid interface to the perforations in the prior
configuration. Finally, the gradient from the intake down to the perforations is
computed. This is done in the same manner as the oil column above, except
that instead of pure oil, the oil/water ratio is assumed to be of the same ratio
as the produced fluids.

Related Topics
Appendix A: References
Multiphase Fluid Properties
Multiphase Correlations
Fluid Properties
Analysis Inputs Overview
Printing Reports

You are here: Analysis Input Windows > Fluid Properties > Fluid Viscosity

Advanced Fluid Viscosity

The Use Advanced Viscosity option allows the user to enter relationships between
viscosity and temperature, shear rate, and/or BS&W (water and sand).
PCPUMP then uses this information to calculate a dynamic viscosity at different
points in the wellbore. This window is accessed by selecting the General
Properties tab in the Fluid Properties tab, selecting Use Advanced Viscosity and
clicking the Specify button.
Note: For multiphase fluid flow, only Temperature Effects are available.

Advanced Fluid Viscosity Input Window

Specifying Advanced Viscosity Information

In the Data tab, the effects of temperature, non-Newtonian properties, and
produced water on fluid viscosity can be defined.
Temperature Effects
Crude oil viscosity is typically dependent on temperature. Depending on
the overall magnitude of viscosity, this dependency may influence the
design of a PC pumping system.
To activate this feature, select

Specify Temperature Effects.

Enter the viscosity (for single-phase flow) or dead oil viscosity (for
multiphase flow) at a range of temperatures into the table. At least
two data points are required to define the relationship.
Note: In multiphase flow, the program considers the specified values
to be dead oil viscosities and will utilize a correlation to account for
solution gas content to obtain the downhole (live) oil viscosity.
The best-fit relationship between the viscosity and temperature will be
automatically calculated after each data point is entered using the
following equation:

(cp) = A T (C)B
20Where:
30
is the viscosity (for single-phase flow) or dead oil viscosity (for
multiphase flow) of the fluid, cp
T is the temperature of the fluid, C
A, B are calculated correlation coefficients
The two calculated correlation coefficients A and B will be displayed below
the table.
The relationship can be viewed graphically by selecting "Temperature
Effects on Viscosity" from the Chart drop-down list in the Charts tab.

Advanced Fluid Viscosity Chart Window

Note: If Temperature Effects are used, ensure that you have entered the
appropriate bottomhole temperature, temperature gradient and/or flowing
wellhead temperature inputs.
Non-Newtonian (Shear Thinning) Effects
Note: This option is not available when multiphase fluid type is selected.
Most petroleum fluids tend to be non-Newtonian, often exhibiting
pseudoplastic (shear thinning) behaviour. This behaviour can have a

considerable impact on fluid flow behaviour.

PCPUMP's flow algorithms have the ability to model non-Newtonian fluids.
Further information on this topic can be found in Single-Phase Fluid Flow Technical Considerations.
To activate this feature, select

Specify Non-Newtonian Effects.

Enter the oil viscosity at a number of shear rates into the

corresponding table. At least two data points are required to define
the relationship.
The best-fit mathematical relationship between the viscosity and shear
rate will be automatically calculated after each data point is entered using
the following equation:
(cp) = K (1/s)N
Where:
is the viscosity of the fluid, cp
is the shear rate, 1/s
K, N are calculated correlation coefficients
The power law fluid model coefficients consistency (K) and flow behavior
(N) will be displayed below the table.
The non-Newtonian fluid relationship can be viewed graphically by
selecting "Shear Rate Effects on Viscosity" from the Chart drop-down list in
the Charts tab.
Note: When Temperature Effects and Non-Newtonian Effects are selected
simultaneously, the temperature data forms the base curve while the flow
behavior index is used to adjust for shear rate effects.
BS&W Effects
Note: This option is not available when multiphase fluid type is selected.

Water content will also affect the viscosity of the produced fluid.
To activate this feature, select

Specify BS&W Effects.

Enter the viscosity of the oil itself in the corresponding input box.
If you have selected Temperature Effects or Non-Newtonian Effects,
the oil viscosity will automatically be calculated from the selected
correlation(s).
Use one of the following three methods to calculate the viscosity of the
oil/water mixture:
1. Weighted average of the oil viscosity and water viscosity.
In this case, the program varies the mixture viscosity between the
oil and water viscosities as a linear function of the BS&W content
(sum of the sand and water cuts) using the equation:
(m) = (oil) (1-BS&W) + (BS&W) (BS&W)
Where:
(m) is the mixture viscosity, cp
(oil) is oil viscosity, cp
(BS&W) is water viscosity, cp
BS&W is content, %
No input parameters are required for this method.
click Linear With BS&W Content.
2. Emulsion correlation.
(m) = (oil) exp(

C BS&W)

for 0 < BS&W < Fi

(m) = (BS&W) for Fi < BS&W < 100

Where:

To activate,

(m) is the mixture viscosity, cp

(oil) is oil viscosity, cp
(BS&W) is water viscosity, cp
BS&W is content, %
C is the maximum viscosity factor
Fi is the inversion fraction, %
Two options are available when using the emulsion correlation:
Default
This correlation assumes that the mixture viscosity increases
with BS&W content to a maximum value 8.67 times the oil
viscosity (C = 8.67) at a BS&W content of 60% (Fi=0.60). At
BS&W contents above 60%, it is assumed that the emulsion is
inverted and the mixture viscosity is equal to the water
viscosity. No further input parameters are required for this
method. To activate, click Default Emulsion Correlation.
Custom
This correlation is similar to the default emulsion correlation.
It allows the user to specify the maximum viscosity and the
BS&W content at which the emulsion becomes inverted.
To activate, click Define Emulsion. You must specify both the
Maximum Viscosity Factor, which is a multiplication factor
applied to the viscosity of the oil to define the maximum
mixture viscosity, and the Inversion Fraction point, which
defines the BS&W content at which the mixture viscosity drops
to the water viscosity.

The best-fit mathematical relationship between the viscosity and BS&W

will be automatically calculated.
The effects of BS&W content on viscosity can be viewed graphically by
selecting the appropriate charts from the Chart drop-down list in the Chart

tab.

Note: All changes are automatically saved. The software will directly apply the
advanced viscosity relationships you specify to obtain the mixture viscosity.

Related Topics
Fluid Properties
Single-Phase Fluid
Properties
Multiphase
Properties
Analysis Inputs
Overview
Using Tables and
Charts
Printing Reports

Fluid

You are here: Analysis Input Windows > Fluid Properties > Fluid Thermal Properties

Fluid Thermal Properties

If you select the Pump Friction Analysis in the Options window, or are modeling
a downhole drive system and have chosen the Motor Heating Analysis in the
Options window, then you must describe fluid heat transfer properties before
the calculation may proceed. See the Analysis Options section for more
information.
The fluid thermal properties are specified using the Thermal Properties tab in
the Fluid Properties window.

Thermal Properties Input Window

Specifying Fluid Thermal Information

Heat transfer calculations require the Fluid Specific Heat Capacity (Cp) and the
Fluid Thermal Conductivity (K) of the produced fluids.
Note: The Fluid Thermal Conductivity (K) is only required for downhole drive
motor heating analysis.
Heat transfer calculations in multiphase flow also use the specific heat capacity
of the gas, which is specified in the Preferences window (see the Setting
Program Preferences section). This gas property will generally have little
effect on the overall (mass-weighted) mixture heat capacity as liquids will
normally constitute the bulk of the mass flow rate.
There are two ways in which you may specify the specific heat capacity and
thermal conductivity values in PCPUMP.
1. You may directly specify bulk thermal properties for the produced fluids by
selecting User Specified and entering values for Cp and K.
2. If you are using the single-phase flow mode and have selected Calculate Fluid
Density in the General Properties tab, or if you are using multiphase flow,
you can have PCPUMP calculate mixture thermal properties using oil and
BS&W fractions in the produced fluids by selecting Derived from Fluid
Composition.

PCPUMP calculates mixture values as linear functions of the component

volume and mass fractions for the thermal conductivity and specific heat
capacity, respectively. Thermal properties may be specified in one of the
following two ways.
Use the PCPUMP default thermal properties values for oil and water
activated by selecting Use Default Values.
Specify the thermal properties for the oil and BS&W components and
have PCPUMP calculate values for the mixture based on the
composition. This option is activated by selecting Specify Values.

Related Topics
Fluid Properties
Analysis Inputs
Overview
Using Tables and
Charts
Printing Reports

You are here: Analysis Input Windows > Fluid Properties > Diluent Injection Effects

Diluent Injection Fluid Properties

The diluent injection fluid information is specified using the Diluent Injection
tab in the Fluid Properties window and is only available when an injection
tubing string has been specified. Ensure that Single-Phase is selected at the top
of the tab window.

Diluent Injection Fluid Properties Input Window

Specifying Diluent Injection Fluid Information

1. The first two inputs ask you to specify the Diluent Flow Rate and the
Diluent Density.
2. You have the option to

Specify Diluent Viscosity

or to

Use Advanced Diluent Viscosity.

The advanced viscosity table works in the same way as the advanced
viscosity for the produced fluids but you can only specify a
viscosity/temperature relationship for the diluent.
PCPUMP uses the following equation to combine the viscosity of the
produced fluids with the viscosity of the diluent:
log(mix) = (1-DF) log(prod) + DF log(diluent)

Where:
mix is the viscosity of the mixture, cp
prod is the viscosity of the produced fluids, cp
diluent is the viscosity of the diluent, cp
DF is the diluent fraction of the combined fluids (by volume)
Note: If you selected

Specify BS&W Effects

in the Fluid Advanced Viscosity

option (for the produced fluids), PCPUMP will mix the diluent and oil
together first, using the above equation, and then calculate the overall
mixture viscosity by blending the oil/diluent mix with the water using the
method you select in the Fluid Viscosity window (for the produced fluids).

Related Topics
Fluid Properties
Analysis Inputs
Overview
Using Tables and Charts
Printing Reports

You are here: Analysis Input Windows > Operating Conditions > Overview

Operating Conditions
The operating conditions information
Conditions tab.

is specified using the

Operating

Operating Conditions Input Window

Specifying Operating Conditions

Operating Information
1. Produced Fluid Flow Rate (surface): Total surface fluid rate at standard
conditions. This rate includes the oil, water, and sand components of the
produced fluid.
2. Pump Speed: Rotational speed of the PC pump.
3. Motor Operating Frequency:
For downhole drive module only.
The
frequency of the electrical power supplied to the downhole electric motor.
This frequency may differ from the power supply frequency. Downhole
motors are normally controlled by a variable speed or frequency drives
(VSD, VFD), which allows speed control by converting input power from
the supply frequency to the desired motor operating frequency.
4. Fluid Level: Distance from surface to the top of the annular fluid column.
To specify this value with respect to measured depth (mKB or ftKB),
vertical depth (Vertical m or Vertical ft) or joints to fluid (jts), toggle the
unit button to the right of the fluid level value to the desired units. Note
that PCPUMP assumes that one joint of fluid is equivalent to a measured
length of 9.6 m.
5. Submergence (measured): The Fluid Level subtracted from the Pump
Seating Depth to give the measured depth of submergence.
6. Bottomhole Pressure: Pressure at the mid-perforation location during
production.
Surface Pressure Information
1. Tubing Head Pressure: Tubing head pressure.
2. Casing Head Pressure: Casing head pressure.
Temperature Information

1.

Specify Temperature

Bottomhole Temperature: Fluid temperature at the mid-perforation

location.
Temperature Gradient: The reduction in tubing fluid temperature per
unit vertical depth as it travels to surface.
Flowing Wellhead Temperature: Temperature of fluid flowing through
wellhead.
Note: This parameter should not be entered manually when the Pump
Friction Analysis or Motor Heating Analysis options are turned on in the
Options tab.
2.

Specify Temperature Profile:

You have the option of creating a producing fluid

temperature profile by selecting this option and clicking the Specify button.
This option should not be used when the Pump Friction Analysis or Motor
Heating Analysis options are turned on in the Options tab.

Some operating conditions are interdependent, and by specifying one you

define another. For example, consider fluid rate and pump speed: For a given
pump displacement and volumetric efficiency, either parameter can be
calculated based on the value input for the other. To address interdependent
parameters, PCPUMP uses radio buttons to select the input parameter.
The operating conditions you need to specify will be dependent on whether or
not an inflow performance relationship (IPR) is available. The IPR defines a
direct relationship between the produced fluid rate and the bottomhole
pressure. An IPR correlation can be activated by checking Specify IPR data and
clicking Specify.
(See the Inflow Performance Relationship section for a
description of how to specify an IPR.) If an IPR is not selected, you will see the
Operating Information area divided by a line. In this case, you must enter
either the fluid rate, pump speed, or motor operating frequency (downhole
drive only), AND the fluid level, measured submergence or bottomhole
pressure. If an IPR is active, the dividing line will be removed and only one of
the options must be entered.
Warning:
Extra care must be taken when using the multiphase fluid
properties option when an IPR is not active. The pump intake pressure
calculated in PCPUMP is affected by the casing head pressure and fluid level
and by the amount of free gas which is separated and diverted up the
casing/tubing annulus. This effect may make comparative analyses somewhat
complicated. For instance, in order for the producing pressure to remain
constant in several analysis cases with the same free gas separation efficiency,
flow rate, and casing head pressure but different pump seating depths, the
fluid level in the annulus must change accordingly. This is because the

amount of free gas in the casing/tubing annulus changes with different pump
seating depths, which affects the annulus pressure gradient and consequently
the pump intake pressure. Therefore, for the results to be meaningful, you
must select the input conditions carefully when performing analyses using
these options.

Related Topics
Temperature Profile
Inflow Performance Relationship
Analysis Inputs Overview

You are here: Analysis Input Windows > Operating Conditions > Temperature Profile Input

Temperature Profile
When a temperature profile is available, PCPUMP's Temperature Profile window
can be used to create a temperature profile for the producing fluid and/or
ground temperature.
The producing fluid Temperature Profile window is accessed from the main
Operating Conditions window by selecting the Specify Temperature Profile radio
button in the Temperature Information area.

Temperature Profile Input Window

Specifying a Temperature Profile

The temperature profile is constructed using a series of temperature points
along the wellbore measured depth.
1. For each data point, enter the Measured Depth and the Producing Fluid
Temperature at that depth. Rows are automatically sorted by measured
depth.
Data points can be inserted into the table by selecting the row below the
desired insertion point, right-clicking, and selecting "Insert Row". Data
points can be deleted by highlighting their corresponding rows, rightclicking and selecting "Delete Row(s)". To delete all segments in the table,
right-click and select "Clear All Rows".
2. The temperature profile can be viewed graphically in the accompanying
Chart.

Once you have finished entering the temperature profile, click the

OK

button.

To abort your design and return to the Operating Conditions window, click the
Cancel button.

Related Topics
Operating Conditions
Inflow Performance
Relationship
Analysis Inputs Overview
Using Tables and Charts
Printing Reports

You are here: Analysis Input Windows > Operating Conditions > Inflow Performance Relationship

Inflow Performance Relationship

Inflow into a well depends on the pressure difference between the reservoir
and the wellbore. With static reservoir pressure fixed and bottomhole flowing
pressure variable, the difference between the two, called drawdown, will
determine the flow rate. Flow rate will increase with drawdown, with the
maximum flow rate occurring at 100% drawdown or zero bottomhole flowing
pressure.
Inflow performance relationships (IPR) define the correlation between the fluid
flow rate and the producing (bottomhole) pressure.
The IPR is specified using the IPR window which is located off the Operating
Conditions window by selecting Specify IPR data at the top of the window and
clicking the Specify button.

Inflow Performance Relationship (IPR) Input Window

Specifying an Inflow Performance Relationship

PCPUMP supports the following five common IPR types, which are listed under
the Relationship Type portion of the window. Each IPR type is discussed in the
subsequent section.
Single Point
Straight Line (with Data Point)
Straight Line (PI)
Vogel
Multiple Point
Backpressure (Fetkovich)
Quadratic (Jones, Bloot and Glaze)
Composite
Standard Composite
Once an IPR type is selected, you can enter data for the required input

parameters under the Test Data portion of the window. The non-applicable
parameters are greyed-out.
Below is a list of all the input parameters:
Static Reservoir Pressure: Static reservoir pressure.
Bubble Point Pressure: Bubble point pressure.
Note: The specified value must be equal to (i.e. saturated reservoir) or
less than (i.e. undersaturated reservoir) the static reservoir pressure.
Productivity Index: Ratio between the producing pressure and the fluid
rate.
Producing Pressure - Test Points #1 & #2: Producing bottomhole pressure
(at mid-perforations) for the corresponding test point.
Note: Test Point #2 only needs to be specified for multiple point IPR's.
Fluid Rate - Test Points #1 & #2: Surface fluid rate for the corresponding
test point.
Note: Test Point #2 only needs to be specified for multiple point IPR's.
BS&W Content - Test Point #1: Volumetric percentage of basic sediment
and water in the produced fluid measured at surface.
Note: This input is only specified for a Composite IPR.

Once all the necessary data is entered, the chart on the right-hand side of the
window is automatically updated with the IPR relationship information. This
chart shows producing bottomhole pressure as a function of fluid rate and
extends from zero flow rate (producing pressure = static reservoir pressure) to
the maximum flow rate (producing pressure = zero). If the Composite IPR
type is selected, the chart will contain separate curves for oil and BS&W rates
as well as the BS&W content.
The IPR window allows you to calculate a Producing Pressure at a target Fluid Flow
Rate or vice versa.
To do this, select the desired Target Conditions at the
bottom right-hand side of the window, and enter the target value into its
corresponding edit box. The target conditions will be displayed on the
IPR chart. Note that the target conditions are not used in the main
calculations.

Once you have finished entering the inflow performance relationship data,
click the OK button in the bottom right-hand corner of the screen to confirm
your inputs and return to the Operating Conditions window.
To abort any
changes and return to the Operating Conditions window, click the Cancel button.

IPR - Technical Considerations

Single Point
Straight Line (PI)

&

Straight Line (with Data Point)10 :

This is a simple IPR equation which states that the production rate is
directly proportional to pressure drawdown in the reservoir. The
constant of proportionality is called the productivity index, PI (or J in
some literature), and is defined as the ratio of the flow rate to the
pressure drop between the reservoir and the wellbore.
Because the straight line IPR is derived from Darcy's law for the
steady-state incompressible flow of a single-phase fluid, its use should
be limited to undersaturated oils or water.
A straight line IPR can be calculated either based on a single test point
and the static reservoir pressure ("with Data Point" option) or based on
the productivity index and the static reservoir pressure ("PI" option).
Vogel11 :

The Vogel IPR is traditionally used to describe oil well

performance when both oil and gas phases may flow in the reservoir.
Vogel's equation is a best-fit approximation of numerous simulated
well performance calculations. It is commonly used because of its
simplicity and accuracy and only requires the static reservoir pressure,
bubble point (for undersaturated reservoirs) and a single test point.
Note:PCPUMP applies the Vogel equation below the bubble point and a
straight-line IPR above the bubble point.
Multiple Point
Backpressure (Fetkovich)12 :

The Backpressure IPR for oil wells uses the

same type of equation typically used for analysing gas wells.
Assuming the static reservoir pressure is known, this method requires
two test points.

Parameters in the backpressure relation include the flow coefficient, C,

and an exponent, n, which depends on well characteristics.
Glaze)10 :

Quadratic relationship that is

developed from multi-rate test data and which attempts to
characterize non-Darcy flow effects. Parameters in the relationship
include a laminar flow coefficient, C, and a turbulent flow coefficient,
D. This method requires two test points.
Quadratic

(Jones,

Bloot

and

Composite
Standard Composite13 :

This relationship is well suited for determining the

inflow performance of oil wells producing water. The method uses a
constant PI for the water production and adds it to a Vogel relationship
for the oil production to obtain a composite inflow performance
relationship.
To use this method you need the static reservoir
pressure, bubble point (for undersaturated reservoirs) and a single test
point with both water and oil production rates.

Related Topics
Operating Conditions
Temperature Profile
Analysis Inputs Overview
Using Tables and Charts
Printing Reports

You are here: Analysis Input Windows > Analysis Options

Analysis Options
The analysis options are specified using the Options tab.

Analysis Options Window

Pump Friction Analysis

This analysis option allows you to consider the additional heat generated by
friction within the pump. In steady state operation, this heat is all absorbed
by the fluids passing through (and past) the pump; this will tend to increase
the temperature of the fluid. This can affect the performance of the system if
there is multiphase flow, or if you have selected the option to adjust the
viscosity of the fluid with temperature.
Select the Consider additional heat generated by friction between the rotor and stator checkbox to consider heat from pump friction in the analysis.
Note: When this option is turned on, the program requires that you enter the
specific heat of the fluid. Please see the Fluid Thermal Properties section for
more information on entering thermal properties of the produced fluid.

Viscous Flow Analysis

PC pumps in applications where large volumes of viscous fluids are pumped
have reportedly experienced a larger torque than was predicted by previous
versions of PCPUMP. The increase in torque is due to flow losses within the
pump. Select the Consider increase in torque due to large volumes of viscous fluid checkbox to consider viscous torque in the analysis.
The estimated viscous torque is reported in the Analysis Results tab under
Output Messages in the Summary tab, in the Energy Flow tab, and in the
torque breakdown charts of the Rod Loading/Deflection tab.
Note: PCPUMP will print an output message when this option is used. The
calculation performed in PCPUMP is based on a model developed from limited
amounts of laboratory and field data available to CFER. Therefore, caution is
recommended when performing analyses with this feature turned on.
Note: This feature cannot be used with multilobe pumps.

Motor Heating Analysis

Motor heating analyses are used to calculate the temperature of a downhole
motor and model the fluid temperature increase and resulting property
changes as it passes by the motor. This information is helpful in identifying
operating conditions that lead to motor overheating.
Select the

Perform motor heating analysis and consider fluid property changes due to changes

in fluid temperature

check-box to include this analysis.

Note: When this option is turned on, the program requires that you enter the
specific heat of the fluid. Please see the Fluid Thermal Properties section for
more information on entering thermal properties of the produced fluid.

Motor Heating - Technical Considerations

A submersible electric motor can generate a significant quantity of heat during
operation.
To prevent the electric motor from burning due to excessive
operating temperature, this heat must be dissipated by the produced fluids
flowing past the motor.
In downhole drive applications, two parameters related to motor cooling are of
interest:
the operating temperature of the motor windings and;
the temperature increase of the produced fluid past the motor.
The key motor design parameter is the temperature of the windings, since
excessive winding temperatures may shorten motor life significantly.
Motor manufacturers may provide information on temperature increase of the
windings in relation to the housing temperature as part of the motor
performance curves included in the PCPUMP equipment database.
This
temperature difference between the motor windings and motor housing
surface is a function of motor power loading. It is suggested that you contact
the motor manufacturer to confirm your design if this information or the
maximum acceptable motor winding temperature is not available from the
PCPUMP motor database.
The temperature increase of the produced fluids provokes changes in
important fluid physical properties, such as viscosity, which can affect the
performance of the entire system. PCPUMP calculates the temperature increase
of the produced fluid past the motor using the thermal properties of the fluid.

Heat transfer routines are included in PCPUMP to allow these parameters to be

estimated on the basis of physical principles.54 The routines implement an
improved version of the procedure initially proposed by Powers.55 The increase
in the produced fluid temperature is obtained by equating the heat dissipated
by the motor to the heat absorbed by the produced fluid. The temperature
difference between the motor skin and the bulk of the produced fluid is a
function of the amount of heat to be dissipated and the calculated convective
heat transfer coefficient. This coefficient depends heavily on the flow regime
(laminar or turbulent), flow velocity past the motor and the physical properties
of the fluid. The motor winding temperature increase above the motor skin
temperature is given by the motor performance curves, as a function of motor
load.

Heat Transfer
Select the Consider heat transfer model
check-box to include this analysis.

in calculating temperature profile of produced fluids

For more information on Heat Transfer, see "Heat Transfer Help" and "Heat
Transfer Module" in Related Topics below.

Related Topics
Analysis Inputs
Overview
Fluid Thermal
Properties
Heat Transfer Help
Heat Transfer
Module

You are here: Analysis Input Windows > Case Manager

Case Manager
PCPUMP has been designed to allow you to work with a number of different
analysis configurations simultaneously. This feature is useful for performing
comparative analyses of two or more scenarios, and for modeling both surface
and downhole drive systems for the same application.

Case Manager Section

Using the Case Manager

Visual Cues:
indicates that an input or calculation error has occurred.
indicates that:
a new or modified case has not yet been calculated;
a case completed successfully but warnings were generated; or
that during a batch analysis, some cases generated errors while
others were completed successfully.
indicates that the analysis case completed successfully and no
warnings were generated.
Adding cases: Right-click anywhere in the Case Manager area and select
"Add Case" and a new blank case will be added.
Another option is to duplicate an existing case. Select the case you wish to
duplicate, right-click and select "Duplicate Case". The new case will appear
below with a unique ID value at the end.
Deleting Cases: Select the case you wish to delete, and press the delete
key or right-click and select "Delete Case".
Modifying Cases (drag/drop, updating analysis input windows):
Note that any changes you make in the Equipment Configuration window
only apply to the currently active case. You can switch between existing
equipment cases by selecting their names from the list shown in the

window.
Renaming Cases: Select the case you wish to rename, right-click and
select "Rename Case". Alternatively, left-click on the case you wish to
rename and the case name will change to an edit state.
Note: It is recommended to rename the cases to communicate the
predominant properties of that case. This will help when comparing the
analysis results of different cases.
Exporting Cases: PCPUMP has the ability to save the results of a
calculation to an XML output file. To export a data file, right-click the case
to be exported and select "Export Case". This should be done after
completing a calculation in PCPUMP. Note that the export feature will
export data for the selected case at the selected batch value.
The export feature will generate two XML files. The first is a large,
detailed file, and the other is a smaller file containing the basic
information which can be viewed within PCPUMP, and which can be opened
in Microsoft Excel (or some other spreadsheet programs, such as Open
Office) as a tabbed spreadsheet. This file cannot be opened in versions of
Microsoft Excel earlier than Excel 2003. For most purposes, the smaller
file will be all that is required. If you wish to access more information than
is available in the small file, please contact CFER.
Locking Inputs: Select the case you wish to lock, right-click and select
"Lock Inputs". To unlock, select the case you wish to unlock, right-click and
select "Unlock Inputs".
Exclude From Calculation: Select the case you wish to exclude from the
analysis calculation, right-click and select "Exclude From Calculation". You
can re-include a case by right-clicking and selecting "Include In
Calculation".
Show Messages: Select the case you wish to view analysis messages for,
right-click and select "Show Messages". A window like the one below will
appear which displays any logistical issues that remain unresolved. Should
an error message appear that is not clear or if the software generates an
unexpected error, please use the PC-PUMP Technical Support contact form,
which can be opened by clicking on the link found at the bottom of the

Analysis Calculation Messages window.

Analysis Calculation Messages Window

Case Notes: The "Case Notes" option is used to capture information about
the case. For example, engineering assumptions can be placed in this area
for future reference by the engineer or by clients.

Case Notes Window

Related Topics
Analysis
Configuration
Analysis Inputs
Overview
Printing Reports
Feedback Form

You are here: Analysis Input Windows > Analysis Configuration

Analysis Configuration
After one or more cases have been configured, an analysis can be performed.

Basic Analysis
When the Calculate button is clicked, all cases are analyzed. If there is a
particular case that you do not want calculated, right-click and select "Exclude
From Calculation".
PCPUMP allows you to simultaneously run surface and downhole drive cases.

Batch Analysis
When evaluating PC pumping systems, it is often desirable to perform
assessments for a range of operating conditions (e.g. fluid rates, fluid levels).
This type of analysis can be done most effectively using PCPUMP's Batch
Parameter Analysis calculation mode.
The Batch Parameter section of the window is located in the bottom right
corner. Select Perform Batch Analysis and click the Parameter update button .

Batch Parameter Input Window

To run the Batch Analysis, choose the parameter(s) you want to vary from the
checklist at the left of the Batch Parameter window. Once a parameter is
selected, a column will appear in the Parameters area. Values can be entered
into the selected columns using the auto fill functionality or by copying and
pasting.
To use the auto fill functionality, click on the column header for the parameter
you would like to auto-fill. Enter a starting value to appear in the first row and
an increment or end value to be applied in subsequent rows. Press the Auto Fill
button to populate the table.
Note If potentially conflicting parameters are selected (e.g. Fluid Flow Rate
and Pump Speed, or Gas Liquid Ratio and Gas Oil Ratio), the parameter
furthest left in the table will be used to calculate the case. The selected
columns can be re-ordered by clicking and dragging the column header.

Batch Parameter Column "Click-And-Drag"

Note All parameters listed below are available regardless of the list of cases. It
is possible to select a parameter that will not result in any variation in the
results. For example, selecting the Gas Oil Ratio parameter will not cause a
case using single-phase to vary.
The Batch Comparison allows you the option of varying one of the following
key operating parameters:
Bottomhole Pressure
BS&W: For cases using multiphase fluid properties.
Casing and Tubing Head Pressure
Casing Head Pressure: Either the tubing and casing head pressures can be
varied together, or one of them can be varied individually. When varied
together, the two pressures are considered to be equal at all steps in the
comparison.
Density: For cases using single-phase properties with Specify Fluid Density
selected.
Diluent Rate: For cases using diluent injection.
Diluent Viscosity: For cases using diluent injection.
Downhole Motor Frequency: For cases using a downhole drive system.
Fluid Flow Rate
Fluid Level
Free Gas Separation: For cases using multiphase fluid properties and the
Calculate Free Gas Separation option turned off.
Gas Liquid Ratio: For cases using multiphase fluid properties.
Gas Oil Ratio: For cases using multiphase fluid properties.
Oil API Gravity: For cases using multiphase fluid properties or single-phase
fluid properties with Calculate Fluid Density selected.
Pump Seating Depth
Production Date
Pump Speed
Submergence
Tubing Head Pressure
Viscosity: For cases using single-phase fluid properties, with Use Advanced
Viscosity option turned off.
Water Cut: For cases using single-phase fluid properties.

Note PCPUMP is capable of associating selected Batch Parameters with a

Production Date in order to display calculation results on a time-series graph.
To specify dates, select Production Date from the available Batch Parameters or
check the Specify Time Series Data box in the Batch Parameter window.
Click OK to confirm your input and return to the main window, or click
abort any changes.

Cancel

to

Click the Calculate button. A status bar displays the progression of the
calculation. The first case selected will appear.
A comparison table and chart are available for comparing multiple cases and
multiple batch settings. See the sections on Comparison Table, Comparison
Chart and Comparison Table and Chart Filtering for more information.
Calculation time will depend on the number of equipment cases selected, the
level of calculation complexity and the processing speed of your computer.

Related Topics
Case Manager
Analysis Inputs
Overview
Using Tables and
Charts
Printing Reports

You are here: Analysis Input Windows > Custom Equipment Encryption

Custom Equipment Encryption

PCPUMP can encrypt custom equipment files to protect confidential
information. The encryption algorithm uses the same triple-DES method as the
internal PCPUMP data encryption algorithm. To encrypt a file, open the Custom
Equipment Window by selecting the Tools menu option and click "Custom
Equipment". A check-box labeled Encrypt file contents is available for each
equipment type. (Brake, Cable, Drive Assembly, Downhole Motor and
Progressing Cavity Pump).

Custom Equipment Window

To encrypt a custom equipment file, click the Encrypt file contents check-box and
enter a password. Once a password in entered, the user must click the OK
button in the Password window then the OK button in the Custom Equipment
window to finish encrypting the file.

Encryption Password Entry Window

The password will be now needed to change or view the specifications of

custom equipment when the file is encrypted. Encrypted files will appear with
a lock icon in the custom equipment tree in the Custom Equipment window. In
order to modify or view the specifications of custom equipment, the file must
be unlocked by entering the password. To enter a password, click the Enter
Password button and enter the correct password. The custom equipment model
will be temporarily unlocked until the Custom Equipment window is closed
either by clicking the OK button or the Cancel button. Once the Custom
Equipment window is closed, a password will be required to access that custom
equipment file again.

Custom Equipment Window - Encrypted File

Password Entry for Encrypted File

To permanently unlock an encrypted file, click on the file to be unlocked and

uncheck the check-box labeled Encrypt file contents. Enter the password and click
OK to finish unlocking the file. The file will now be unlocked and not encrypted
until the Encrypt file contents box is clicked and a new password is entered.

Unlocking an Encrypted File

If a password for a data file is lost, the file can be sent to C-FER to unlock. CFER will unlock the file and re-encrypt it with a new password before sending
the file back.

Related Topics
Custom Cable Equipment
Custom Drive Assembly
Equipment
Custom Motor Equipment
Window
Custom Pumps
Backspin Analysis

You are here: Analysis Input Windows > Heat Transfer Help

Heat Transfer Help

PC-PUMP includes a heat transfer module which can be used to calculate the
temperature of the produced fluid. The initial release of the heat transfer
module is limited to use in select cases, specifically when the pump is landed
above the mid-perforations, a single-phase fluid is selected, and a surfacedriven PCP is selected.
The heat transfer module can be activated in the Options window. After
activating the heat transfer module, additional information will need to be
input into the Equipment Configuration window, the Fluid Properties window
and the Operating Conditions window.

Options Window - Heat Transfer Module

Equipment Configuration Window - Heat Transfer Module

After activating the heat transfer module, a number of changes will be made to
the Casing Selection window and the Tubing Selection window in the
Equipment Configuration tab. Note that the Pump Seating Measured Depth
must be less than the Mid-Perforations Measured Depth to use the current heat
transfer module. Additional inputs will also be required in order to perform the
heat transfer analysis:
Tubular Selection Window
With heat transfer activated, the user can enter intermediate and surface
casing in addition to the production casing. These additional casing types are
not a required input, but will affect the amount of heat transfer from the
produced fluid to the surrounding environment during production and
therefore will affect the calculated fluid temperature. These new casing types
are entered in the same way the production casing is entered, with each being
stored in a different tab of the Tubulars window.
Production Casing, Intermediate Casing and Surface Casing:
In addition to the inputs required to enter casing information without heat
transfer activated, there are now two additional inputs for each casing type
that is entered.

Casing Selection Window - Heat Transfer Activated

Thermal Conductivity: The thermal conductivity of the casing material. This

will affect the rate of heat transfer from the fluid through the casing to the
surrounding ground. Steel typically has a thermal conductivity of 45 W/mK
(26 BTU/hftF).
Surrounding Material: The material outside of the casing. A drop-down list is
provided which includes cement, diesel, gelled diesel, light cement, methane
and water. Each material has default thermal properties stored in the program
which will affect the heat transfer calculations.
Ground
In order to complete a heat transfer calculation, PC-PUMP
information about the ground surrounding the wellbore.

requires

Ground Tab in Casing Selection Window - Heat Transfer Activated

Ground Type: Choose the type of ground surrounding the wellbore. Selecting
either "carbonate" or "sandstone" from the drop-down list will allow the
program to use the default information associated with either ground type
stored in PC-PUMPin the heat transfer calculations.
Hole Diameter: Enter the diameter of the wellbore (i.e. the diameter of the
hole drilled).
Time From Start of Production: The number of days since the start of fluid
production is used to determine the temperature of the surrounding ground,
based on the heat transfer that has already occurred since the start of fluid
production.
NOTE: It is recommended that a Time From Start of Production of at least 30
days be entered in order to reflect a case where the heat transfer will be
relatively constant with time.
The Tubing tab now requires the additional Thermal Conductivity input as
discussed in the Tubulars window section above. Steel typically has a thermal
conductivity of 45 W/mK (26 BTU/hftF).

Tubing Selection Window - Heat Transfer Activated

Fluid Properties Window - Heat Transfer Module

With the heat transfer module active, the user must enter thermal properties
for the produced fluid. To enter fluid thermal properties, select the Thermal
Properties tab in the Fluid Properties window. There are two ways in which you
may specify the specific heat capacity and thermal conductivity values in
PCPUMP.
1. You may directly specify bulk thermal properties for the produced fluids by
selecting User Specified and entering values for Cp and K.
2. If you are using the single-phase flow mode (required for heat transfer
calculations) and have selected Calculate Fluid Density in the General
Properties tab of the Fluid Properties window, you can have PCPUMP
calculate mixture thermal properties using oil and BS&W fractions in the
produced fluids by selecting Derived from Fluid Composition.
PCPUMP calculates mixture values as linear functions of the component
volume and mass fractions for the thermal conductivity and specific heat
capacity, respectively. Thermal properties may be specified in one of the
following two ways.
Use the PCPUMP default thermal properties values for oil and water
activated by selecting Use Default Values.
Specify the thermal properties for the oil and BS&W components and
have PCPUMP calculate values for the mixture based on the
composition. This option is activated by selecting Specify Values.

Thermal Properties Tab in Fluid Properties Window

Operating Conditions Window - Heat Transfer Module

After activating the heat transfer module, a ground temperature profile must

be entered into the Operating Conditions tab. The ground temperature profile
is used to determine the fluid temperature at the mid-perforations depth and
the temperature of the ground surrounding the wellbore.

Temperature Profile Window - Heat Transfer Activated

The temperature profile is constructed using a series of temperature points

along the wellbore measured depth.
1. For each data point, enter the Measured Depth and the Ground
Temperature at that depth. Rows are automatically sorted by measured
depth. A ground temperature profile associated with the vertical depth of
every data point entered will be created.
Data points can be inserted into the table by selecting the row below the
desired insertion point, right-clicking and selecting "Insert Row". Data
points can be deleted by highlighting their corresponding rows, rightclicking and selecting "Delete Row(s)". To delete all segments in the table,
right-click and select "Clear All Rows".
2. The ground temperature profile can be viewed graphically in the
accompanying Chart. Since the temperature of the produced fluid is not
available at this time, the column input will remain blank, and the graph
will not show the Producing Fluid Temperature.

Once you have finished entering the temperature profile, click the

OK

button.

To abort your design and return to the Operating Conditions window, click the
Cancel button.
NOTE: Though the Measured Depth is entered with the Ground Temperature,
the temperature profile is associated with vertical depth. This means that in a
horizontal section of the wellbore, the ground temperature will remain
constant.

Final Steps - Heat Transfer Module

Once additional inputs have been entered in the Equipment Configuration
window, the Fluid Properties window and the Operating Conditions window,

click the Calculate button to perform the analysis. PC-PUMP will use the
information entered in order to determine the temperature of the produced
fluid. The temperature profile can be viewed in the Basic Fluid Flow tab of the
Analysis Results window.

Temperature and Viscosity Profiles - Calculated Using Heat Transfer

Related Topics
Heat Transfer Module
Fluid Thermal Properties
Casing String
Tubing String
Temperature Profile

You are here: Analysis Input Windows > Heat Transfer Module

Heat Transfer Module

The heat transfer module can currently only be used in limited circumstances
where the user must select a single-phase fluid, use a surface driven PCP, and
have the pump above the perforations.
Please contact C-FER for any suggested improvements and expansion of the
heat transfer module if you require additional functionality beyond what is
included in this version of the software. Any user input regarding future
development of the heat transfer module is appreciated.

You are here: Analysis Results Windows > Calculation Messages

Analysis Calculation Messages

There are many considerations that you may wish to address when evaluating
PC pumping systems. To highlight possible problem areas, PCPUMP tests the
analysis results against some common design criteria. Problems encountered
during the calculation process, as well as other relevant information, generate
a message that is then displayed in the Analysis Calculation Messages pop-up
window and in the Output Messages section of the Summary tab.

Analysis Calculation Messages Pop-up Window

Analysis Summary Output Messages Area

The Analysis Calculation Messages pop-up window is enabled by selecting

Display output messages after calculation in the Default Switches tab of the
Preferences window. If the pop-up window is disabled, these messages are still
available for viewing in the Output Messages area in the Summary tab of the
Analysis Results window, and you should always read them, whether or not
you decide to enable this feature.
PCPUMP displays three different types of output messages. These are:
"
NOTE" which indicates adjustments or assumptions made during the
analysis.
" WARNING" which indicates potential problems with the current system
design.
"
ERROR" which means there were errors in the calculation that were
not serious enough to prevent completion of the calculation but that could
indicate there is some aspect of the design that will not work properly.
Results with an "ERROR" message should be considered inaccurate.
Should an error message appear that is not clear or if the software generates
an unexpected error, please use the PC-PUMP Technical Support contact form,
which can be opened by clicking on the link found at the bottom of the Analysis
Calculation Messages window.

You are here: Analysis Results Windows > Analysis Overview

ANALYSIS RESULTS
Within the main Analysis Results tab, sub-tabs allow you to access the
following output detailed analysis results information:
Summary: Display of important fluid properties, operating conditions and
output parameters commonly used to measure system performance.
Energy Flow: Table which provides a breakdown of the energy consumed
by the various system components.
Drive Equipment: Specifications related to the operating conditions of
either the surface drive or downhole drive equipment. Sub-tabs allow you
to view separate windows for the different components of the system. This
window is only available if drive equipment was specified in the Equipment
Configuration window.
Basic Fluid Flow: Charts that display basic fluid flow information (e.g.
pressure, temperature and viscosity profiles).
Rod Loading/Deflection:
Charts which display rod string loading and
deflection results.
Rod/Tubing Contact: Charts that display rod/tubing contact loads.
Multiphase Flow: Charts that display multiphase flow information (e.g.
liquid holdup, flow regime).
Key Locations: Table that displays important parameters for several key
locations (e.g. pump intake, surface).
Within the main Auxiliary Analysis tab, sub-tabs allow you to access
supplementary analyses that are not completed in the standard calculation
routines. These analyses require additional input data.
Rod/Tubing Wear: Auxiliary analysis window in which you input additional
data in order to assess rod string and tubing wear for surface drive
systems.
Rod String Fatigue: Auxiliary analysis window in which you input additional
data in order to assess rod string fatigue for surface drive systems.
Backspin: Auxiliary analysis window in which you input additional data in
order to evaluate rod string backspin behavior for surface drive systems.
Sand Settling: A tool to determine if the velocity in the tubing is sufficient
to carry entrained sand to surface.
You can also view the results of comparison calculations in tabular and chart
format by clicking the Show Analysis Comparison Table button under the Analysis

Comparison section on the right-hand side of the main window. For more
information on analysis comparison, see the Comparison Table and Comparison
Chart sections.
Note: If changes are made to any of the input tabs, the results will require
recalculation by clicking the Calculate button.

Related Topics
Using Tables and Charts
Printing Reports
Exporting Data

You are here: Analysis Results Windows > Summary Information > Analysis Summary

Analysis Summary
When you perform calculations using PCPUMP, a whole array of results are
generated. A summary of the results is presented in the Summary tab of the
Analysis Results tab, which is shown below.

Analysis Results Summary Window

To use PCPUMP effectively, it is important that you are familiar with the type of
information that is available and the best ways to examine it. You should also
recognize that some results are contingent upon the specification of certain
inputs (e.g. in order to get rod/tubing contact loads for surface drive systems
you must input a wellbore geometry).

Summary of Input Parameters

On the left-side of the Analysis Results tab, the specified or calculated fluid
properties and operating conditions are displayed.
For example, if you
specified the fluid flow rate in the Operating Conditions input window, the
corresponding pump speed will be displayed in the Operating Conditions box.
Drive, pump and rod information are listed as well.

Summary of Output Parameters

When evaluating PC pumping systems, there are certain parameters that are
commonly used to measure system performance. For convenience, the most
important of these parameters are displayed on the right-side of the Analysis
Results tab. Some of these are always available while others are only shown
when appropriate. Summary output parameters are listed below.
The following parameters are applicable to both surface drive and downhole
drive systems:
Pump Intake Pressure: Pressure at the inlet to the pump.
Pump Discharge Pressure: Pressure at the pump discharge.
Differential Pressure: Pressure differential across the pump.
Net Hydrostatic Head: Total differential head between the fluid columns in

the tubing and annulus, expressed as a pressure.

Flow Losses: Cumulative flow losses, expressed as a pressure, through the
entire flow path (casing, tail joint or shroud, and tubing).
Pump Pressure Loading: Pressure loading of the pump as a percentage of
its rated pressure capacity.
Pump Torque: The amount of torque required to operate the pump at the
given conditions.
Pump Axial Load: The axial load transmitted by the pump to the rod string
or downhole drive assembly.
Energy Cost: Energy cost per day based on active power consumption.
This parameter is only shown if drive equipment has been included in the
analysis. Note that the unit power cost can be assigned in the Default
Values tab under the Preferences window or in the Drive Equipment
window.
System Mechanical/Electrical Efficiency: derived from the mechanical or
electrical efficiencies of each individual system component, and represents
the portion of the total system input power that is used to overcome the
hydraulic component of the pump torque at the pump's operating speed.
System Overall Efficiency: the percentage of the total system input power
that contributes to increasing the pressure of the produced fluids (and any
associated gas) across the pump. This is equivalent to the System
Mechanical/Electrical Efficiency multiplied by the Pump Volumetric
Efficiency.
These parameters are specific to surface drive systems:
Maximum Rod Torque: Maximum torque that occurs in the rod string.
Maximum Rod Torque Load:
Maximum torque in the string as a
percentage of the maximum torque rating for the rod.
Maximum Axial Rod Load: Maximum axial load that occurs in the rod
string.
Maximum Effective Rod Stress: Maximum rod string effective stress in
terms of a percentage of the rod yield strength.
Maximum Contact Loads: Maximum contact load between the rod string
and the tubing.
System Input Power: Electrical power required to operate the system.
This parameter is only shown if drive equipment has been included in the
analysis.
Prime Mover Output Power: The shaft power output of the prime mover in

the surface drive equipment.

Energy Cost: Average cost of electrical energy in $/kWh.
Note: This parameter is initially assigned a value based on the default set
in the Preferences window.
Thrust Bearing L10 Life:
Length of time (in years and millions of
revolutions) that 90% of the thrust bearings will operate before the first
evidence of fatigue develops. Within a large sample size, the median
bearing life is somewhere between four and five times the L10 life.
Drivehead Main Shaft Torque Loading: Main shaft torque loading as a
percentage of its maximum allowable limit.
Drivehead Structural Loading: Structural loading of the drivehead frame
as a percentage of its maximum capacity.
Drivehead Power Output: Drivehead power output as a percentage of
rated maximum.
Drivehead Speed Output: Output speed of the drivehead as a percentage
of its rated maximum continuous rotational speed.
Drivehead Gearbox Torque: Gearbox torque as a percentage of its AGMA
rating (N/A if a gearbox is not included).
Surface Motor Loading: The shaft power output of the prime mover in the
surface drive equipment.
These parameters are specific to downhole drive systems:
Cable Conductor Temperature: The calculated maximum temperature of
the conductor in the electrical cable.
Motor Winding Temperature: The calculated maximum temperature of the
motor windings.
Motor Output Power: The shaft power output of the downhole electric
motor.
Drive Assembly Thrust Loading: Thrust loading on drive assembly as a
percentage of its maximum thrust rating.
Drive Assembly Torque Loading: Torque loading on drive assembly as a
percentage of its maximum torque rating.
Drive Assembly Power Loading: Power loading on drive assembly as a
percentage of its maximum power rating.
Drive Assembly Speed Loading: Speed loading on drive assembly as a
percentage of its maximum speed rating.
Downhole Motor Loading: Loading on motor as a percentage of its
maximum rating.

These parameters are specific to systems with diluent injection pumps:

Discharge Pressure: Pressure at the injection tubing discharge.
Hydrostatic Head: Total head of the fluid column in the injection tubing,
expressed as a pressure.
Flow Losses: Cumulative flow losses, expressed as a pressure, through the
entire flow path of the injection tubing.

Output Messages
Problems detected during the calculation process are displayed in the Output
Messages section at the bottom of the window.

Output Messages

PCPUMP displays three different types of output messages. These are:

"NOTE" which indicates adjustments or assumptions made during the
analysis.
"WARNING" which indicates potential problems with the current system
design.
"ERROR" which means there were errors in the calculation that were not
serious enough to prevent completion of the calculation but that could
indicate there is some aspect of the design that will not work properly.
Results with an "ERROR" message should be considered inaccurate.

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You are here: Analysis Results Windows > Summary Information > Energy Flow

Energy Flow
The Energy Flow tab traces the use of power through the individual PC
pumping system components and shows where power is being consumed
within the overall system. If the results show that a particular component has
an unacceptable efficiency, you may want to reconsider its use. For example,
when surface drive hydraulics operate outside of their designed speed and
pressure range, they experience dramatic reductions in efficiency.
The Energy Flow tab is divided into two sections: Mechanical Power Train and
Hydraulic Power Train.
The electrical/mechanical power train breakdown
(upper half of the window) isolates the power consumption of each component
of the system, and is specific to the type of drive system in use (surface or
downhole). The power input and output of each component is shown along
with the associated power loss and resulting mechanical and/or electrical
efficiency.
The hydraulic power train (lower half of the window) provides a detailed
breakdown of the power consumed by the progressing cavity pump. This
includes the effective torque and power associated with each of the
components contributing to the differential pressure acting on the pump, along
with the pump friction torque. Contributing pressures include the hydrostatic
head, wellhead pressure differential, and flow losses. Both the hydrostatic
head and wellhead pressures are displayed in terms of the net pump
differential pressure that they create. When added to the flow losses, they
generate the total pressure load in the pump.

Energy Flow - Surface Drive Systems

The Energy Flow tab for surface drive systems is shown below. The upper half
of the window describes the flow of energy from the prime mover through
auxiliary surface equipment and the rod string to the pump. Components not
applicable to the selected equipment configuration are greyed-out on the
screen. With the exception of the rod string, each of the surface drive system
power train components is self explanatory. Rod String (Rod/Tubing Friction)
represents the frictional losses that occur due to mechanical contact between
the rotating rod string and stationary tubing. Rod String (Resistive) represents
the frictional losses due to viscous interaction between the rotating rod string
and the fluid in the tubing.

Energy Flow Output Window Surface Drive Systems

Energy Flow - Downhole Drive Systems

The Energy Flow tab for downhole drive systems appears as shown below. The
upper half of the window describes the flow of energy from the power
transmission cable through the motor and drive assembly to the pump. This
window allows you to determine if any of the components are performing
inefficiently, to assist with system optimization. For example, an undersized
cable can cause a large voltage drop and dissipate more power than necessary.

Energy Flow Output Window Downhole Drive Systems

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You are here: Analysis Results Windows > Summary Information > Drive Equipment

Drive Equipment
The Drive Equipment tab provides a detailed breakdown of the performance of
each component of the drive system and addresses key concerns for
equipment selection. Like the Energy Flow tab, the appearance of the Drive
Equipment tab changes depending on whether a surface drive or downhole
drive system is active. Once you are in the Drive Equipment tab, additional
sub-tabs at the top allow you to move between dialogues showing detailed
outputs for each component of the selected drive system.

Surface Drive Equipment

The Drive Equipment tab for surface drive systems displays results for the
drivehead, belts (if selected), hydraulics (if selected) and prime mover. By
examining the results presented for each component's loading conditions
relative to the manufacturers' ratings, you can determine if the surface
equipment components are sized appropriately. Additionally, by moving from
component to component, the transmission of speed, torque and power can be
traced from the drivehead back to the prime mover.
Drivehead
The Drivehead sub-tab is shown below.

Drive Equipment - Drivehead Output Window

At the top of the window, the drivehead Model, Type, Gearbox Reduction (if
applicable) and Transmission Efficiency are displayed.
Below these, the
following operating conditions are listed:
Speed: Drivehead output speed (i.e. the polish rod speed) and input speed
(i.e. the belt/sheave/hydraulic/motor speed).
Torque: Drivehead output torque (i.e. the polish rod torque) and input
torque (i.e. the belt/sheave/hydraulic/motor torque).
Power: Drivehead output power (i.e. the polish rod power) and input power
(i.e. the belt/sheave/hydraulic/motor power).
Thrust Bearing L10 Life:
Length of time (in years and millions of
revolutions) that 90% of the thrust bearings will operate before the first

evidence of fatigue develops. Within a large sample size, the median

bearing life is somewhere between four and five times the L10 life.
Main Shaft Torque Loading: Main shaft torque loading as a percentage of
its maximum allowable limit.
Structural Loading:
Structural loading of the drivehead frame as a
percentage of its maximum capacity.
Power Output:
Drivehead power output as a percentage of rated
maximum.
Output Speed: Output speed of the drivehead as a percentage of its rated
maximum continuous rotational speed.
Gearbox Torque: Gearbox torque as a percentage of its AGMA rating (N/A
if a gearbox is not included).
Belts
The Belts sub-tab is shown below.

Drive Equipment - Belts Output Window

Since belts are an optional component, this window might be blank to indicate
their absence in the current equipment configuration. The Reduction Ratio and
Transmission Efficiency of the belt and sheaves system are displayed at the top
of the window. If the Match pump speed by adjusting belt reduction ratio / hydraulic pump
displacement option for speed matching was selected (see the Prime Mover
section), then the reduction ratio is likely to be different from the value
originally specified during equipment selection (because the surface equipment
speed will have been matched to the pump speed by changing the belt
reduction ratio). In the lower portion of the window, values for the following
operating conditions are listed:
Speed: Belt and sheaves system output speed (i.e. to the drivehead) and
input speed (i.e. from the motor).
Torque: Belt and sheaves system output torque (i.e. to the drivehead)
and input torque (i.e. from the motor).
Power: Belt and sheaves system output power (i.e. to the drivehead) and
input power (i.e. from the motor).
Hydraulics
The Hydraulics sub-tab is shown below.

Drive Equipment - Hydraulics Output Window

Since hydraulics are an optional input, this window may be blank indicating
that hydraulics are not present in the current equipment configuration.
Information for the hydraulic motor and pump are displayed on the left-hand
and right-hand sides of the window, respectively.
The Hydraulic Motor specifications listed are:
Model: Hydraulic motor manufacturer and model.
Displacement: Volume of fluid required to produce one revolution of the
hydraulic motor.
Total Efficiency: Overall operating efficiency of the hydraulic motor.
Power: Hydraulic motor input power from the hydraulic pump and output
power to the belts, sheaves or drivehead.
Fluid Flow Rate: Hydraulic motor flow rate to pump.
Operating Pressure: Hydraulic motor operating pressure.
Output Speed: Output shaft speed generated by the hydraulic motor.
Output Torque: Output shaft torque generated by the hydraulic motor.
Pressure Load: Hydraulic motor operating pressure as a percentage of its
maximum continuous rating.
Operating Speed: Hydraulic motor output speed as a percentage of its
rated maximum continuous operating speed.
Output Power: Hydraulic motor output power as a percentage of its rated
maximum power.
The Hydraulic Pump specifications listed are:
Model: Hydraulic pump manufacturer and model.
Full Displacement: Maximum volume of fluid that can be displaced with
each revolution of the hydraulic pump.
Total Efficiency: Overall operating efficiency of the hydraulic pump at the
existing conditions.
Power: Hydraulic pump input power from the prime mover and output
power to the hydraulic motor.
Fluid Flow Rate: Hydraulic pump flow rate from motor.
Operating Pressure: Hydraulic pump operating (discharge) pressure.
Input Speed: Speed of the hydraulic pump input shaft.

Input Torque: Torque required on the hydraulic pump input shaft.

Pressure Load: Hydraulic pump operating pressure as a percentage of its
maximum continuous rating.
Operating Speed: Hydraulic pump input speed as a percentage of its rated
maximum continuous operating speed.
Actual Displacement: Actual displacement of the hydraulic pump as a
percentage of its full displacement. If the Match pump speed by adjusting belt
reduction ratio / hydraulic pump displacement option for speed matching was
selected, then the actual displacement may not be 100%. The surface
equipment speed is matched to the downhole pump speed by varying the
hydraulic pump displacement (in practice this would be achieved through
adjustment of its swash-plate).
Prime Mover
The Prime Mover sub-tab is shown below.
The window only displays
information for electric motors, since they are currently the only type of prime
mover supported by PCPUMP .

Drive Equipment - Prime Mover Output Window

At the top of the window, the motor Power Rating, Synchronous Speed (at
operating frequency), nominal Efficiency and nominal Power Factor are
displayed. The following operating parameters are listed in the lower portion
of the window for the electric motor:
Output Speed: Operating speed of the electric motor.
Output Torque: Torque delivered by the electric motor.
Output Power: Power output of the electric motor.
Operating Frequency: Frequency of the motor input power. If the Match
pump speed by adjusting prime mover speed option for speed matching was
selected, then the operating frequency may be different than the supply
frequency. The surface equipment speed is matched to the pump speed by
varying the motor operating frequency to replicate an electronic speed
control system.
Voltage Draw: Voltage drawn by the motor during operation. If the motor
is operating at supply frequency or higher, then this value is equal to the
supply voltage. However, if the operating frequency is less than the supply
frequency, then the voltage draw is decreased to maintain a constant
Volts/Hertz ratio to simulate variable speed control systems operating at

below supply frequency.

Current Draw: Current drawn by the motor during operation.
Power Input: Power drawn by the motor during operation. The left-hand
value (kW or hp) is the active power while the right-hand value (kVA) is
the apparent power.
Energy Cost: Energy cost per day based on active power consumption.
Note that the unit power cost can be assigned in the Default Values tab
under the Preferences window or in the Prime Mover window.
Motor Loading: Loading of the electric motor as a percentage of its power
rating.

Downhole Drive Equipment

The downhole equipment version of the Drive Equipment tab shows detailed
analysis results for the drive assembly, downhole motor and power
transmission cable.
Drive Assembly
The Drive Assembly sub-tab shows the manufacturer Company, Model and
Type of the drive assembly that was selected, along with its Gear Reduction.

Drive Equipment - Drive Assembly Output Window

This window displays the input and output Speed, Torque and Power from the
drive assembly and the calculated overall mechanical Efficiency. The Thrust
Loading, Torque Loading, Power Loading and Speed are shown as a percentage
of the associated rated capacities of the drive assembly.
Motor
The Motor sub-tab summarizes the equipment that was selected and provides
results that describe the operating conditions and performance of the motor.

Drive Equipment - Motor Output Window

It displays a summary of the specifications of the selected motor including the

manufacturer Company, Model, Power Rating, Number of Poles, and Nameplate

Frequency. Performance parameters that are displayed in the window include:

Operating Frequency:
The electrical frequency at which the motor
operates. This frequency may differ from the power supply frequency.
Downhole motors are normally controlled by a variable speed drive (VSD),
which allows pump speed control by converting power from the supply
frequency to the desired motor operating frequency.
Operating Speed: The speed at which the motor output shaft rotates.
Output Power: The shaft power provided to the system by the motor.
Efficiency: The overall mechanical efficiency of the motor.
Operating Voltage: The voltage at which the motor operates.
Power Factor: The ratio of active to apparent power drawn by the motor.
Current Draw: The amount of current required by the motor.
Slip: The difference between the operating speed of the motor and the
synchronous speed at the operating frequency.
Motor Loading: The ratio of the actual motor output power to the motor's
rated power at the operating frequency.
This value is scaled with
frequency, so that the motor rated power will not be the nameplate power
if the operating frequency is not equal to the nameplate frequency.
Flow Velocity Past Motor: The average velocity of the flow in the annulus
between the motor and the casing or shroud.
Motor Skin Temperature: The maximum temperature at the outside
surface of the motor.
Note: Only calculated when Motor Heating Analysis is turned on (see the
Analysis Options section).
Motor Winding Temperature: The maximum temperature of the windings
inside the motor. The winding temperature depends on temperature rise
at operating conditions, and may not be available from manufacturers for
all motors.
Note: Only calculated when Motor Heating Analysis is turned on (see the
Analysis Options section).
Winding Temperature Rating:
The motor manufacturer's maximum
allowable winding temperature specification.
Cable
The Cable tab provides a summary of the specifications of the selected cable.

Drive Equipment - Cable Output Window

At the top of the window, the manufacturer Company, Model, and Type
(round/flat) are displayed. The following analysis results are presented in the
window:
Conductor Temperature: The maximum calculated temperature of the
cable conductor.
Allowable Conductor Temperature: The cable manufacturer's maximum
allowable conductor temperature specification.
Voltage Loss in Cable: The voltage drop in the cable corresponding to the
current draw and conductor temperature.
Motor Voltage: The operating voltage of the motor.
Current Draw: The current passing through the cable to the motor.
Surface Voltage: The voltage at surface.
Power Input at Surface: The total power drawn by the system.
Total Energy Cost: The daily cost of the energy drawn by the system.
Note that the unit power cost can be assigned in the Preferences window
and in the equipment input window.

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You are here: Analysis Results Windows > Summary Information > Basic Fluid Flow

Basic Fluid Flow

The basic fluid flow output results can be accessed by clicking the Basic Fluid
Flow tab.

Basic Fluid Flow Output Window

You can select the following charts from the Chart drop-down list:
Pressure Profiles: Displays the pressure profiles in the casing, tubing and
tail joints or shrouds. Locations of the mid-perforations and downhole
equipment are also labelled on the chart.
Tubing Pressure Components: Displays the pressure profile in the tubing,
as well as a breakdown of the flow loss and hydrostatic head components.
The hydrostatic component is due to the weight of the fluid column. The
flow loss component is due to frictional pressure losses as the fluid moves
through the tubing. Tubing head pressure results in an offset at surface.
Combined, these components generate the total pressure profile in the
tubing.
Tubing Flow Losses: Displays flow loss components for pre-set lengths of
production tubing. For surface drive cases, flow loss is shown for every rod
string element (i.e. individual sucker rod or continuous rod segment). For
each rod segment, different data symbols show the pressure losses
attributed to the rod body, couplings/centralizers and rod guides. In the
case of multiphase flow, only a single flow loss representing the entire
element is shown. For downhole drive cases, tubing flow loss is shown per
joint of tubing.
Temperature and Viscosity Profiles: Displays the fluid viscosity profile along
the length of the tubing and the temperature profiles in the casing and
tubing. For multiphase flow, the viscosity displayed corresponds to the
mixture viscosity determined based on no-slip conditions (i.e. gas and
liquid moving at the same velocity).

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You are here: Analysis Results Windows > Summary Information > Rod Loading/Deflection

Rod Loading/Deflection
Rod strings are used in surface-driven PC pump applications to transfer power
from the surface equipment to the pump. Rod string design considerations
have become increasingly important with the use of PC pumps in higher lift
applications and the development of PC pumps with increasingly higher
displacements. Inadequately designed rod strings will often lead to operational
problems, equipment failures and costly workovers.
The rod loading/deflection output results can be accessed by clicking the Rod
Loading/Deflection tab.

Rod Loading/Deflection Output Window

You can select one of the following charts from the Chart pull-down list:
Rod String Torque and Axial Load Profiles: Displays the torque and axial
load profiles along the length of the rod string. The peak polish rod torque
and tension values are also listed.
Rod String Effective Stress Profile: Displays the effective rod stress profile
along the length of the rod string.
Values are expressed in both
conventional stress units and as a percentage of the rod yield strength.
Note: This chart is only shown for rods that have a yield stress rating in
the equipment database.
Elastic Based Rod String Design: Compares the operating torque to the
torque needed to yield the rod material along the length of the rod string.
Note that the torque at yield strength values have been determined using
combined loading methods which take into consideration the operating
axial load.
Rod String Torque Loading: Compares the operating torque to the
manufacturer's torque limit. The torque ratings do not include any effects

of axial load. Different manufacturers may provide torque ratings based

on different levels of axial load and different safety factors. Currently,
there is no standardized method for determining the torque rating for a
sucker rod.
Note: This chart is only shown for rods that have a torque rating in the
equipment database.
Rod String Torque Breakdown (Incremental): Displays the rod/tubing
contact and viscous loading contributions of each rod string element (i.e.
individual sucker rod or continuous rod segment).
Contact load
contributions result from mechanical friction between the rod string and
tubing. Viscous contributions result from interaction between the rotating
rod string and viscous fluid in the tubing. The graph also shows the pump
hydraulic and friction torque values. The hydraulic component is the
torque required to displace the fluid across the differential pump pressure.
The friction component is the torque required to overcome friction within
the pump.
Rod String Torque Breakdown (Cumulative): Displays the torque
breakdown data as above, but on a cumulative basis along the length of
the rod string.
Rod String Deflection and Rotation: Displays the cumulative axial
deflection and rotation along the length of the rod string under operating
conditions. Total deflection and rotation values are also included on the
chart. Note that the axial deflection values include both rod weight and
operating load extensions but do not include any changes due to thermal
effects.
Rod String Space Out: Displays information useful for determining rod
string space-out requirements for system installation. Curves on the chart
show rod deflection due to rod weight; rod deflection due to operating
loads, rod extension due to thermal effects (see note below), and total rod
deflection.
Also listed are values that correspond to the maximum
deflections for each of these curves as well as a minimum space-out value,
which is the total deflection resulting from operational loading and thermal
effects.
In a basic space-out operation, the rig crew will watch for the rotor hitting

the tag bar, usually indicated by a drop in the hook weight on the rig.
Following that, the crew will pick up the full string weight. Normally, they
will have to pick up more than just the deflection due to rod weight, since
the rods will slump in the well when they are resting on the tag bar.
When the rod weight is picked up, the rotor will just be coming off the tag
bar. After that, the crew must pick up the distance from the tag bar to the
bottom of the stator. At that point, the rotor is where it needs to be during
operation. But the crew must also pick up the distance that the rods are
expected to stretch during operation, so that the rotor will be in that
position once the well is started. That is the minimum space-out value
reported by the program.
Note: If the tubing is anchored, temperature changes will cause the rod
string to lengthen relative to the constrained tubing. If you want to
consider the effects of thermal expansion on space-out requirements, click
the Specify Thermal Effects button above the Rod String Space Out chart,
check the Consider thermal expansion effects on space-out box and enter a spaceout Average Ground Temperature (i.e. the average temperature of the
rods within the wellbore during space-out). The space-out temperature is
assumed to be the average of the bottomhole temperature and the
ambient surface temperature. Click the OK button to view the space-out
chart.

Thermal Effects Window

Technical Considerations
There are three main sources of rod string loading in PC pump applications.
The primary loading is torsional, but axial and bending loads may also
contribute to more severe stress states.
Torsional loading in rod strings is caused primarily by the differential
pressure acting across the pump (hydraulic torque). Friction in the pump
due to the interference fit between the rotor and stator may also
contribute a significant amount of torque (friction torque). Additional
torsional loading occurs due to friction in the rod/tubing contact in
directional well applications. In high-viscosity fluid cases, rod strings may
also experience resistive torque due to fluid shear in the region between
the rods/couplings and tubing.

Axial loading (tension) in rod strings is generated by the differential

pressure acting across the PC pump and by the weight of the rod string.
The latter component becomes more severe towards the top of the well.
Some compressive axial load may also be encountered if the fluid is of an
adequate viscosity to cause area uplift forces on the faces of couplings
and/or centralizers and surface uplift forces due to fluid shear on the
surfaces of the rod string components.
The figure below summarizes the major sources of torque and axial load in
a PC pumping application.

Rod String Torque and Axial Load Components

Bending loads have typically been regarded as insignificant compared to

torsional and axial loadings. This is primarily because wellbore curvatures
are usually not severe enough to cause any significant amount of bending
stress. However, an investigation completed by CFER has shown that
tension in the rod string can magnify the rod curvature near sucker rod
couplings to be five or more times the wellbore curvature. This is largely
due to the difference in stiffness between the couplings and the rod body
as well as the rod body standoff from the production tubing wall near
points of coupling-tubing contact.
Consideration of bending loads is
especially critical in fatigue evaluations.
There are a number of methods typically used to determine the severity of the
rod loading. The majority of design methods start by calculating an effective
(overall) stress in the material caused by the combination of torsional and
axial loadings. PCPUMP uses the von Mises criterion47 (also referred to as the
Maximum Distortion Energy criterion) to determine the maximum effective
stress in the cross-section of the rod. This stress is then compared to the
elastic stress limit (yield strength) of the material. Elastic-based design
procedures normally limit the rod stress level to the material's yield strength.
A second loading analysis method, based on plasticity theory, has been
included in the PCPUMP rod string loading calculations. Rod strings can
typically withstand 20 to 30 percent more torque than that determined using
elastic design theory before failure will occur. Normally this reserve capacity is
used as a safety factor that protects the rod string against failure during
severe loading conditions such as startup or fluid or sand slugging. It may also

serve to protect the rods against fatigue failures. The deformation-based

theory used in PCPUMP is intended to indicate how severe the calculated rod
loading is relative to the most severe loading the rod could withstand, with no
safety factor. The loading limit is determined by a maximum allowable plastic
strain value of 0.2% and assumes the material is perfectly ductile.
PCPUMP calculates the torque, axial load, and effective curvature at each
segment of the rod string. The elastic-based loading analysis method is used
to determine the effective stress in each rod. The elastic and deformationbased theories are then used to determine the maximum allowable torque at
the material yield strength and at the plastic deformation limit, respectively.
As an indication of overall elastic rod loading severity, the program calculates
the elastic design factor, or EDF, which is the ratio of the effective stress in the
rod to the material yield strength.
Manufacturers were given the opportunity to decide whether the rod stress
calculation in PCPUMP should be applied to their rods. Therefore, some rods
may use the above formulations, while others report load as a per cent of
rated load. Some rods use both methods, and may have slightly different
results in each method.

Comments
Tapered Rod Strings
Tapered rod strings are not normally used in PC pump applications, because
torque is the main contributor to stress, and the torque level does not
generally change significantly along the rod length. (This is in contrast to
beam pump systems where tapered strings are fairly common--and where they
do work, since the stress in those applications is due to axial load, and that
does change significantly with depth due to rod weight.)

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You are here: Analysis Results Windows > Summary Information > Rod/Tubing Contact

Rod/Tubing Contact
The rod/tubing contact output results are accessed by selecting the Rod/Tubing
Contact tab.

Rod/Tubing Contact Output Window

You can select one of the following charts from the Chart pull-down list:
Rod/Tubing Contact Loads: Displays the contact loads for each rod string
element (i.e. individual sucker rod or continuous rod segment). Different
data symbols are used for couplings/centralizers, rod guides and
continuous rod. The contact loads for couplings, centralizers and rod
guides are expressed as point loads per connection. In the case of
continuous rod, the contact loads are expressed as a linearly distributed
load in the specified force per distance units. Note that the charts will only
display data for rod components included in the specified equipment
configuration.
Rod/Tubing Distributed Contact Loads: Displays contact loads for each rod
string element expressed as a distributed load. This chart is intended to
facilitate contact loading comparisons between conventional sucker rods
and continuous rod. Distributed contact loads for couplings, centralizers
and rod guides are determined by proportioning their point contact loads
along their load bearing (i.e. contacting) length. Different symbols are
used to differentiate the results for couplings/centralizers, rod guides and
continuous rod.
Rod/Tubing Contact Locations: Graphically illustrates the location of the
rod contact within the tubing. The contact location is displayed as azimuth
values ranging from 0 to 360. Looking up through the tubing from the
pump to surface, the high side of the hole is assigned a contact location of
0. The contact location then increases in a clockwise direction around the
circumference of the tubing (i.e. low side of the hole = 180). This graph
is useful in determining whether high contact loads are occurring on the
low side of the wellbore. This condition can be quite detrimental from a

wear perspective if the well is producing abrasive fluids.

Rod Guide Loading and Spacing: Displays for each sucker rod, the average
rod guide contact load and number of guides per rod. This chart is helpful
if you are utilizing the Rod Guide Optimization mode and want to view the
optimized configuration.

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You are here: Analysis Results Windows > Summary Information > Multiphase Flow

Multiphase Flow
Once you have completed an analysis using multiphase fluid properties, the
multiphase flow output results can be accessed by selecting the Multiphase
Flow tab.

Multiphase Flow Output Window

You can select one of the following charts from the Chart pull-down list:
In-Situ Flow Rates: Displays the in-situ gas, water and oil rates through
the tubing and tail joint or shroud. The location of the pump is marked to
illustrate the crossover between the tubing and tail joint or shroud.
Produced Gas: Displays the free gas percentage, the solution gas/oil ratio
(GOR) and the solution gas/water ratio (GWR) throughout the tubing
string and tail joint or shroud. Note that the free gas percentage is based
on the ratio of free gas flow to total flow (i.e. as opposed to the percentage
volume occupied in the tubing, tail joint, or shroud). Also included on the
chart are the producing gas/oil ratio, tubing gas/oil ratio and casing gas
rate values.
Solution Gas: Displays the GOR and GWR throughout the tubing string and
tail joint or shroud. This data is also available in the Produced Gas chart,
but is better scaled for viewing in this tab with GOR and GWR on separate
axes.
Flow Pattern: Displays the flow pattern types throughout the tubing string
and tail joint or shroud. Types of flow patterns include: single-phase
liquid, bubble, dispersed bubble, slug and annular. The flow pattern may
progress from single-phase liquid to bubble or dispersed bubble to slug as
the fluid moves from the pump discharge to surface.
Liquid Holdup: Displays two-phase and no-slip liquid holdup throughout the

tubing string and tail joint or shroud. The two-phase liquid holdup is the
volume fraction of liquid in the tubing or tail joint during two-phase flow.
The no-slip holdup, sometimes called input liquid content, is the volume
fraction of liquid in the tubing or tail joint that would exist if the gas and
liquid flowed at the same velocity (i.e. no slippage). Holdup values vary
from zero for single-phase gas flow to one for single-phase liquid flow.
Note that when significant gas production occurs, the two-phase holdup
will be higher than the no-slip holdup indicating gas slippage past the
liquid.

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You are here: Analysis Results Windows > Summary Information > Key Locations

Key Locations
The key locations output results shown below can be accessed by clicking the
Key Locations tab.

Key Locations Output Window

This window contains a table with each row corresponding to one key location
in the well. The values in the top part apply to the tubing stream (after gas
separation) and the values in the bottom part apply to the casing stream
(before gas separation). Parameters that do not apply will have a value of
"N/A" displayed in the table.
Tubing Stream
Flowline at Standard Conditions of 101.3 kPa (14.7 psia) & 15.6C (60F);
Wellhead at Tubing Head Pressure;
Pump Discharge;
Pump Intake;
Motor Bottom (for downhole drive cases only); and
Tail Joint Intake (for surface drive cases only, and only if tail joint is
specified).
Casing Stream
Ventline at Standard Conditions of 101.3 kPa (14.7 psia) & 15.6C (60F);
Wellhead at Casing Head Pressure;
Casing Gas/Liquid Interface;
Pump Intake;
Motor Bottom (for downhole drive cases only);
Tail Joint Intake (for surface drive cases only, and only if tail joint is
specified); and
Mid-Perforations.
The table summarizes the calculated values for the following key parameters
(rates and properties are given at in-situ pressure and temperature) at each

key location:
Measured Depth;
Vertical Depth;
Fluid Temperature;
Fluid Viscosity;
Pressure;
Total Fluid Flow Rate;
Oil Rate;
Diluent Rate;
BS&W Rate;
Free Gas Rate;
Free Gas Percent;
Solution GOR; and
Solution GWR.
When diluent injection is used, some more information is given, as shown in
the example below:

In this case, the injection is into the tubing at 600 mKB. This is reflected in
the viscosity and diluent flow rate from this point (which has a row in the
Tubing section of the table) up to surface. The difference between the
pressure in the tubing and the pressure in the injection string at this point (as
shown in the bottom line of the table) is the pressure loss calculated through
the injection nozzle. The injection tubing pressure is shown at the wellhead.
In some cases this may be a negative number, which would mean that the
specified diluent flow rate would be able to be injected by gravity alone.

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You are here: Analysis Results Windows > Comparison Tables and Charts > Time Series Results

Time Series Results

If you have completed an analysis which included batch parameters and
production dates, you can access a time series results window. The graph in
this window displays the effect of changes in the batch parameter on
numerous other system parameters over time. This window can be accessed
by clicking the Tools menu option and selecting "Analysis Comparison Table" or
by clicking the Show Analysis Comparison Table button on the right-side of the main
window. In the Analysis Comparison window, select the Time Series Results
tab.

Analysis Comparison - Time Series Results Window

The Time Series Results tab contains a time-series chart on which specified
parameter group can be plotted on the primary or secondary y-axis. Users may
choose to plot the following parameters:
Pump Speed
Volumetric Efficiency
Fluid Flow Rate
Fluid Level
Submergence
Pump Seating Depth
Producing Pressure
Energy Costs
System Input Power
Pump Intake Pressure
Pump Discharge Pressure
Pump Pressure Loading
Bottomhole Temperature
Net Hydrostatic Head
Flow Losses
Prime Mover Output Power
Polish Rod Power
Maximum Rod Torque

Rod Torque Loading

Maximum Axial Rod Load
Maximum Effective Rod Stress
Elastic Design Factor
Deformation Design Factor
Maximum Contact - Continuous Rod
Maximum Contact - Connection
Maximum Contact - Rod Guide
Downhole Motor Operating Frequency
Downhole Motor Output Power
Pump Torque
Pump Axial Load
Cable Voltage Drop
Cable Conductor Temperature
Flow Velocity Past Motor
System Mechanical/Electrical Efficiency
Overall System Efficiency
Free Gas Separation
Multiphase Flow Apparent Volumetric Efficiency
Free Gas as Pump Intake
Drivehead Thrust Bearing L10 Life
Drivehead Main Shaft Torque Loading
Drivehead Structural Loading
Drivehead Power Output
Drivehead Speed
Drivehead Gearbox Torque
Surface Motor Loading
Drive Assembly Thrust Loading
Drive Assembly Torque Loading
Drive Assembly Power Loading
Drive Assembly Speed Loading
Downhole Motor Loading
Downhole Motor Skin Temperature
Downhole Motor Winding Temperature
Diluent Rate
Diluent Viscosity
Gas Oil Ratio

Gas Liquid Ratio

Sand Cut
Water Cut
BS&W Content
Maximum Tubing Wear Rate
Minimum Rod Fatigue Life
These parameters are defined in the Analysis Summary section.
Note: Not all parameters will have information as some show information for
surface drive cases and others show information for downhole drive cases.
Refer to the Comparison Table and Chart Filtering section to prevent
parameters with no information from being displayed.

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Comparison Table and Chart
Filtering
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You are here: Analysis Results Windows > Comparison Tables and Charts > Comparison Tables

Comparison Table
If you have completed an analysis which included batch parameters, you can
access a comparison table window. This table provides a tabular display of the
results for each of the scenarios run. This window can be accessed by clicking
the Tools menu option and selecting "Analysis Comparison Table" or by clicking
the Show Analysis Comparison Table button on the right-side of the main window. In
the Analysis Comparison window, select the Table tab.

Analysis Comparison - Table Window

The upper portion of the Table tab contains a large table with the results
presented in each row corresponding to an individual scenario and the columns
containing numerous operating parameters. Scroll bars allow you to examine
all of the information in the table. In the lower portion of the window, a
Summary of the system configuration for the currently active scenario is
displayed. The active scenario can be changed by highlighting the row of
interest in the table.
The following parameters are included in the comparison Table output window:
Case
Pump Description
Pump Displacement
Pump Pressure Rating
Pump Speed
Volumetric Efficiency
Fluid Flow Rate
Fluid Level
Submergence
Pump Seating Depth
Producing Pressure
Energy Costs
System Input Power
Pump Intake Pressure

Pump Discharge Pressure

Pump Pressure Loading
Bottomhole Temperature
Net Hydrostatic Head
Flow Losses
Prime Mover Output Power
Polish Rod Power
Maximum Rod Torque
Rod Torque Loading
Maximum Axial Rod Load
Maximum Effective Rod Stress
Elastic Design Factor
Deformation Design Factor
Maximum Contact - Continuous Rod
Maximum Contact - Connection
Maximum Contact - Rod Guide
Downhole Motor Operating Frequency
Downhole Motor Output Power
Pump Torque
Pump Axial Load
Cable Voltage Drop
Cable Conductor Temperature
Flow Velocity Past Motor
System Mechanical/Electrical Efficiency
Overall System Efficiency
Free Gas Separation
Multiphase Flow Apparent Volumetric Efficiency
Free Gas as Pump Intake
Drivehead Thrust Bearing L10 Life
Drivehead Main Shaft Torque Loading
Drivehead Structural Loading
Drivehead Power Output
Drivehead Speed
Drivehead Gearbox Torque
Surface Motor Loading
Drive Assembly Thrust Loading
Drive Assembly Torque Loading

Drive Assembly Power Loading

Drive Assembly Speed Loading
Downhole Motor Loading
Downhole Motor Skin Temperature
Downhole Motor Winding Temperature
Diluent Rate
Diluent Viscosity
Gas Oil Ratio
Gas Liquid Ratio
Water Cut
Sand Cut
BS&W Content
Maximum Tubing Wear Rate
Minimum Rod Fatigue Life
Comments
These parameters are defined in the Analysis Summary section.
Note: Not all parameters will have information as some show information for
surface drive cases and others show information for downhole drive cases.
Refer to the Comparison Table and Chart Filtering section to prevent
parameters with no information from being displayed.

Options
The Current View section allows you to switch between two options:
1.

Cases in table for single batch parameter value

This option allows you to show results for all cases for a particular batch
parameter value. A slider is then available to move between each batch
parameter value.
2.

Batch parameter values in table for single case

This option allows you to display results for each batch parameter value for
a single case. A drop-down list is then available to allow you to move
between cases.

Note: This option is only available when a batch analysis is run.

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You are here: Analysis Results Windows > Comparison Tables and Charts > Comparison Charts

Comparison Chart
If you have completed an analysis which included batch parameters, you can
access a comparison chart window. These charts provide a graphical display
showing the effect of changes in the batch parameter on numerous other
system parameters. This window can be accessed by clicking the Tools menu
option and selecting "Analysis Comparison Table" or by clicking the Show Analysis
Comparison Table button on the right-side of the main window. In the Analysis
Comparison window, select the Chart tab.

Analysis Comparison - Chart Window

The Chart tab contains a series of different Calculated Parameter charts that
can be displayed with the specified Input Parameter displayed on the x-axis.
Calculated Parameter values specified in each Case will also be plotted and
marked with a red circle. The values calculated for the current case inputs are
circled in red (as shown in the diagram above). The Calculated Parameter
drop-down list lets you select different charts which allow the y-axis to be
changed among the following parameters:
Pump Speed
Volumetric Efficiency
Fluid Flow Rate
Fluid Level
Submergence
Pump Seating Depth
Producing Pressure
Energy Costs
System Input Power
Pump Intake Pressure
Pump Discharge Pressure
Pump Pressure Loading
Bottomhole Temperature
Net Hydrostatic Head
Flow Losses
Prime Mover Output Power

Polish Rod Power

Maximum Rod Torque
Rod Torque Loading
Maximum Axial Rod Load
Maximum Effective Rod Stress
Elastic Design Factor
Deformation Design Factor
Maximum Contact - Continuous Rod
Maximum Contact - Connection
Maximum Contact - Rod Guide
Downhole Motor Operating Frequency
Downhole Motor Output Power
Pump Torque
Pump Axial Load
Cable Voltage Drop
Cable Conductor Temperature
Flow Velocity Past Motor
System Mechanical/Electrical Efficiency
Overall System Efficiency
Free Gas Separation
Multiphase Flow Apparent Volumetric Efficiency
Free Gas as Pump Intake
Drivehead Thrust Bearing L10 Life
Drivehead Main Shaft Torque Loading
Drivehead Structural Loading
Drivehead Power Output
Drivehead Speed
Drivehead Gearbox Torque
Surface Motor Loading
Drive Assembly Thrust Loading
Drive Assembly Torque Loading
Drive Assembly Power Loading
Drive Assembly Speed Loading
Downhole Motor Loading
Downhole Motor Skin Temperature
Downhole Motor Winding Temperature
Diluent Rate

Diluent Viscosity
Gas Oil Ratio
Gas Liquid Ratio
Sand Cut
Water Cut
BS&W Content
Maximum Tubing Wear Rate
Minimum Rod Fatigue Life
These parameters are defined in the Analysis Summary section.
Note: Not all parameters will have information as some show information for
surface drive cases and others show information for downhole drive cases.
Refer to the Comparison Table and Chart Filtering section to prevent
parameters with no information from being displayed.

Related Topics
Comparison Table
Comparison Table and Chart
Filtering
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You are here: Analysis Results Windows > Comparison Tables and Charts > Comparison Table and Chart
Filtering

Comparison Table and Chart Filtering

The comparison table and charts have the ability to display a large amount of
information about different cases. However, with such a large number of
columns (in the table) and charts, it can sometimes be difficult to find specific
information.
You can change the data being displayed, and the order in which it is
displayed, by selecting the Options tab in the Analysis Comparison window.

Analysis Comparison - Options Window

In the Options tab, the left-hand column contains all the parameters that can
be displayed in the Table or Chart tabs. Next to each parameter, you can
choose to either "Always Show", "Never Show", or "Show Only If Applicable".
There are also buttons at the top of the window which allow you to Set all to
Always Show, Set all to Never Show or Set all to Show If Applicable.
Minimum and maximum filters can be set for any of the parameters listed. Any
case outside the range entered will be highlighted in grey. To clear the filters
for all parameters, click on the Clear Filters button.
You can also change the order in which the parameters are displayed by
selecting the parameter you wish to move, then clicking the up
and down
arrows on the right-side of the screen to move this parameter to the desired
location in the list. To reset the parameter list to the default arrangement,
click on the Reset Columns to Default Order button at the bottom of the window.

Related Topics
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Comparison Chart
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Printing Reports
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You are here: Analysis Results Windows > Auxilliary Analysis Windows > Rod/Tubing Wear

Rod/Tubing Wear Analysis

Directional and horizontal wells produced with PC pumping systems are prone
to frequent rod string and tubing wear-related problems. These problems can
result in costly workovers and lost production.
Rod/tubing contact loading is calculated based on the wellbore geometry and
the calculated axial load at each point in the rod string. Note that the wear
calculations are completed in a special module outside the main calculation
loop.
The rod/tubing wear analysis module can be accessed by clicking on the
Rod/Tubing Wear tab in the Auxiliary Analysis window.

Rod/Tubing Wear Analysis Window

Rod/Tubing Wear Analysis Configuration

Rod String Wear Coefficients
The table at the top of the window displays the rod string segments that
were selected for the current analysis and wear rate coefficients assigned
to each rod segment.
The coefficients describe the characteristic behavior of the material in
contact with the production tubing. These coefficients are used with the
below empirical wear formula:
W = 1.9548x10-5 X 10(0.075 Y
Where:
W = Tubing Wear Rate (mm/MRevs)
S = Sand Cut (%)
F = Distributed Contact Load (N/m)

S)

X,Y = Wear Coefficients

This formula was developed through a CFER study on rod/tubing wear50.
The empirical wear data suggested that wear rates were linearly related to
rod/tubing contact loads and exponentially related to sand cut.
The wear coefficients must be specified for each type of rod string element
that could come into contact with the tubing including rod connectors
(couplings/centralizers), rod guides, or the surface of continuous rod
string.
There are two ways to change the wear coefficients:
1. If you only want to change one value, select the cell that you want to
change and update the table directly.
2. If you want to update more than one row, select the rows you want to
update and click the Assign Wear Coefficients button.

Wear Coefficients Window

At the top of the Wear Coefficients window, three wear coefficient input
options are available: Steel Defaults, Urethane Defaults and Custom. The
steel and urethane defaults were established through the CFER wear
study. PCPUMP automatically assigns either the steel or urethane
coefficients to each section of rod in the well. To assign different
coefficients, select the Custom input option and enter the appropriate

set of wear coefficients.

The Wear Coefficients window also displays a set of curves which show
the calculated wear rates as a function of localized and distributed
contact loads and different sand cuts for the selected set of wear
coefficients.
Note: To revert the wear coefficients to their default state (1.00 for metal
and 0.90 for non-metal), click the Load Default Wear Coefficients button.
Analysis Conditions
In the Sand Cut box, enter the volumetric percentage of sand in the
produced fluid. The sand cut used in defining the system will be entered
as a default value.
Note: The wear correlation used in PCPUMP has been benchmarked against
field results to sand cuts of 15%. Care should be taken in using sand cuts
above this level.
Target Time
In the Target Time box, enter the period of operation over which you
would like to examine the wear state at the most severely worn point in
the tubing string.

Note: The rod/tubing wear analysis is automatically updated after each field
is changed.

Rod/Tubing Wear Analysis Results

The rod/tubing wear results are displayed in the following tabs under the
Results section at the bottom of the window:
Rod/Tubing Wear: The maximum tubing wear rate and the corresponding
location along the wellbore are displayed in the middle of the window. The
maximum tubing wear that would occur within the period defined by the
specified target time is also shown.
Tubing Wear Profile 1: Shows the tubing wear rate in mm of wall loss per
million revolutions at each segment of the rod string.

Tubing Wear Profile 2: Shows the tubing wear rate as a percentage of the
nominal tubing thickness per year at each segment of the rod string.
Tubing Wear vs. Time: Shows the cumulative tubing wear as a function of
time at the most severe wear location along the wellbore.

Technical Considerations
Rod string and tubing wear rates are typically governed by four factors:
1. Rod/Tubing Contact Loading.
Deviated wellbores lead to contact between the rod string and the
production tubing. The amount of wear at any contact point will depend
on the contact force between the rod string element and the tubing
surface.
2. Rod/Tubing Configuration
The contact loading generated between the rod string and tubing is
dependent on the inside diameter of the tubing and the rod string
configuration. Continuous rod tends to follow the tubing surface because
there are no connections to offset the rod body from the tubing wall as
there are in standard sucker rod strings. Rod guides and centralizers used
with standard rods may increase the wall standoff, but may also distribute
the contact loading over several locations as opposed to only at the rod
couplings. Since the rod element contact force is distributed over the
surface contact area, wear will be reduced if the total contact area is
increased. This can be done by adding more guides or selecting longer
guides.
Tubing wear rates will also depend on the coupling/centralizer/rod guide
material. Field trials have shown that urethane rod guides or centralizers
reduce the amount of tubing wear, but they should not be used where
contact loads exceed 220 N (50 lb). Contact the product manufacturer for
detailed load specifications and limits.
3. Produced Fluid Conditions
Studies indicate that the amount of sand in the wellbore fluid has a
significant effect on the wear rate of tubing and rod string components.50
The sand cut of a fluid is determined using a basic sediments and water

(BS&W) analysis.
4. Rod String Rotational Speed
Wear rates are proportional to the relative speed of the contacting
surfaces. Larger diameter components have higher surface velocities than
small components, and therefore tend to cause more wear per revolution.

Although the program accurately calculates the curvature-induced contact

loads and corresponding wear rates based on the well geometry, equipment,
and operating conditions specified, you may find the predicted wear profiles do
not match field observations. This may be due to the presence of curvature
reversals along directional wellbores which cause localized increases in the
contact loads. The "Hole Angle Change" chart in the Wellbore Geometry
window can be used to verify if curvature reversals exist. Note that in many
cases the survey data available may not accurately portray the overall
magnitude or variation in the curvature along the wellbore.
In addition, the sand cut along the low side of a directional or slant well will
likely be much higher than the average cut measured at surface. This effect
should be considered in cases where the rod/tubing contact occurs on the low
side as well.
The "Rod/Tubing Contact Locations" chart in the Rod/Tubing Contact tab of the
Analysis Results window indicates the location of the rod contact within the
tubing. It is recommended that sensitivity analyses be completed if you are
investigating wear-related problems experienced in the field.

Related Topics
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Boronized Tubing
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You are here: Analysis Results Windows > Auxilliary Analysis Windows > Rod Fatigue

Rod String Fatigue

Mechanical components which are subject to alternating loads are susceptible
to metal fatigue. Repeated variations in stress tend to cause small cracks to
eventually propagate far enough to cause complete component failure.
Fatigue failures can occur even if the peak stress level in the material is below
the yield strength.
Use of the analytical capabilities in PCPUMP will help to determine if there is
potential for fatigue failures to occur in a particular PC pump application. The
rod axial load, torque, and effective curvature are coupled with rod geometry,
material properties, and a user-specified indication of possible alternating
loads to determine the expected fatigue life at each segment in the rod string.
The rod string fatigue module can be accessed by clicking the Rod String
Fatigue tab in the Auxiliary Analysis window. Note that fatigue calculations are
conducted separately from the primary calculation loop.

Rod String Fatigue Analysis Input/Output Window

Rod String Fatigue Analysis Configuration

The PCPUMP software is capable of performing fatigue analyses for entire rod
strings (sucker rod or continuous rod).
The following five parameters must be entered before the fatigue calculation
can proceed:
Rod Ultimate Strength: The ultimate tensile strength of the rod material.
The default value of this input corresponds to the ultimate strength of the
rod grade selected when the rod string was specified.
Surface Finish Type: The surface finish of the sucker or continuous rod.
The choices available include: forged, hot rolled, machined, and cold
drawn. Most sucker rods are hot rolled (the default value), although
specific rod manufacturers may use different fabrication techniques for
special rods. The drop-down list box lists the surface finish types in order
of decreasing susceptibility to fatigue damage.
Torque Amplitude: Half of the total amount of fluctuation observed or

expected in the operating torque magnitude.

Axial Load Amplitude: Half of the total amount of fluctuation observed or
expected in the operating axial load magnitude.
Fluctuation Period: The average duration of each torque and axial load
fluctuation.
If you do not anticipate alternating torque or axial load conditions in your
application, you may still want to conduct a fatigue analysis as alternating
bending loads may be generated due to wellbore curvature.
Once the input parameters have been specified, click the
conduct the fatigue analysis.

Calculate

button to

Rod String Fatigue Analysis Results

Results of the fatigue analysis are displayed on the following table and
charts:
Base Case: Results of the "base case" analysis corresponding to the input
conditions specified are shown in terms of the minimum rod fatigue life
and the corresponding location in the rod string most susceptible to a
fatigue failure. The Elastic Design Factor (EDF) and Deformation Design
Factor (DDF) at this location are also listed.
Note: To see the DDF, the
Preferences window.

Use DDF calculations

option must be selected in the

Sensitivity Analysis: Displays the minimum fatigue life of the rod string
predicted for several different operating conditions. The top table shows
the results for a range of torque values and the bottom table shows the
results for a range of axial loads.
The table text will vary in color according to the severity of the rod
loading. Black text indicates that the EDF and DDF are both less than one,
blue text indicates that the EDF is greater than one and the DDF is less
than one, and red text indicates that both the EDF and DDF are greater
than one. If the DDF option is turned off, then black text indicates that the
EDF is less than one and red indicates that the EDF is greater than one.
Measured Depth vs. Life: Displays the fatigue life for the specified loading
scenario at each point in the rod string. The text box on the chart

summarizes the "base case" alternating load input conditions. Points over
100,000 days are plotted as 100,000 days.
Minimum Lift vs. Torque Amplitude: Displays the predicted minimum
fatigue life of the rod string at a number of alternating torque amplitudes
and fluctuation periods given a single axial load fluctuation amplitude.
Minimum Life vs. Axial Load Amplitude: Displays the predicted minimum
fatigue life of the rod string for several different load fluctuation periods as
a function of the amplitude of the alternating axial load at one alternating
torque amplitude.

Technical Considerations
Fatigue analyses typically attempt to estimate the operating life of a
component. The fatigue life of a component is affected by the average (mean)
stress it experiences, the magnitude of fluctuations in the applied stress, and
the frequency of these stress fluctuations.
Because both high and low
frequency fluctuations may be present, the Palmgren-Miner rule47,48 has been
employed to model the overall fatigue damage per unit time.
Fluctuations coupled with a high mean stress cause more severe fatigue
damage than fluctuations of a similar magnitude but with no mean stress.
Some steels exhibit an endurance limit, the maximum alternating stress that
will result in an "infinite" fatigue life. Designing for alternating stress levels
below the endurance limit serves as an excellent design criterion.
Unfortunately, however, this infinite fatigue life concept does not apply to
many medium and high strength steels (which sucker rods are often made of),
nor does it apply in corrosive environments. PCPUMP does not consider the
possibility of infinite fatigue life.
The operating conditions in many PC pumping applications expose the rod
strings to severe load fluctuations. Variations in pump discharge pressure
caused by gas in the production tubing or increases in pump friction due to
sand or fluid slugs can cause significant fluctuations in pump torque and axial
load.
Rods in deviated wells undergo rotating bending stresses at the
rotational frequency of the pump. It is important to consider fatigue analyses
when these loading conditions occur.
The figure below shows field measurements of very severe load fluctuations

caused by gas slugging.53

Field Measurements of Severe Torque and Axial Load Fluctuations

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You are here: Analysis Results Windows > Auxilliary Analysis Windows > Backspin Analysis

Backspin Analysis
The development and use of larger displacement and higher pressure capacity
PC pumps has led to a substantial increase in the magnitude of the torsional
strain and fluid energy that becomes stored in the production system during
normal pumping operations. The stored energy is released whenever the PC
pump system is shut down due to routine operator intervention or automatic
power cut-off such as in overload cases where the pump seizes or sands up.
Backspin occurs whenever a surface-driven PC pumping system shuts down.
When the power supply to the drive is lost or interrupted, the potential energy
that remains in the system will cause the surface equipment and drive string
to accelerate in the direction opposite to its normal operating mode.
In many applications, if unrestrained by the surface drive/brake equipment,
backspin speeds can increase to the point where the drivehead sheaves or
motor fans will fragment and "explode" radially outward due to the high
centrifugal forces that are generated.
The backspin analysis module can be accessed by clicking on the Backspin tab
under the Auxiliary Analysis tab. The backspin calculation is conducted
independently of the main calculation loop and will only function if you have
already completed the primary analysis and have entered surface equipment.

Backspin Specifications Window

Analysis Specification
The following values must be entered prior to performing a backspin
calculation:
Electric Motor
Power Rating: The rated power of the electric motor.
Poles: The number of poles on the electric motor.
Inertia: The mass moment of inertia of the electric motor.

Belts
Driver/Driven Sheave - Diameter: The outside diameter of the driver
and driven sheaves.
Driver/Driven Sheave - Inertia: The mass moment of inertia of each
sheave about its axis of rotation.
Drivehead
Bearing/Gear Box Reduction: The reduction ratio of the bearing or
gear box (if applicable).
Bearing/Gear Box Inertia: The mass moment of inertia of the gear box.
Surface Equipment Friction: The total dynamic friction of the surface
equipment between the polish rod and the prime mover, which includes
the stuffing box friction, expressed in terms of polish rod torque.
Note: This input field should always be greater than zero.
Brake Specifications: See below for setting the brake specifications.
Pump
Description: Information about the pump.
Friction: The friction torque of the pump.
Volumetric Efficiency: Static value for the volumetric efficiency of the
pump under normal operating conditions.
Fluid Properties
Density: Average density of the fluid in the production tubing.
Viscosity: Average viscosity of the fluid in the production tubing.
Note: Clicking on the Load Specification Defaults button updates the motor,
drivehead, pump and fluid specifications (except inertia values) to the values
corresponding to the equipment/operating case which is currently selected in
the Auxiliary Analysis window.
Note: If you do not know the motor, sheave, and bearing/gear box inertia
values for the selected equipment, the program is equipped with a set of
default values that should serve as reasonable estimates. The default sheave
inertia values are based on typical inertia values for the respective sheave
sizes. Default motor inertia values are assigned based on the number of
poles and the horsepower inputs specified. Bearing/gear box inertia defaults

vary with the reduction ratio. The default values can be assigned by clicking
on the Load Inertia Defaults button after ensuring the other values have been
entered.
Brake Specifications Configuration
To specify brake information, click on the
of the window.

Specify

button in the Drivehead area

Custom Brake Input Window

1. On the left-side of the Custom Equipment window, you can select a custom
brake database. Each database may contain one or more custom brake
models. Once a database is selected, the names of these models will
appear under it. Highlighting a particular brake model will display the
specifications of the selected model. If an existing brake model is selected
to be edited, proceed to Step 4.
2. To create a new custom brake file click the Add File button. This will bring up
a window into which you must enter a Brake Description and a File Name.
Although a file name is automatically created, you can modify it within the
lower edit box. When finished, click the OK button.

New File: Custom Brake Window

3. Once a database has been selected, new custom brake models can be
created by selecting the database name and clicking the Add Model button.
When you select the new model, you can enter the model specifications
into the series of edit boxes on the right-side of the screen.

Custom Brake Model Input Window

4. The following specifications are required for custom brake models:

Braking Location: The brake may act at the polish rod, gear pinion, or

prime mover. If the "Polish Rod" option is selected, the brake torque
will be based on the rotational speed of the polish rod. By selecting
"Gear Pinion", the gearbox speed ratio will be taken into account and
the rotational speed of the gearbox input shaft will be used to calculate
the brake torque. The "Prime Mover" option will apply brake torque
based on the electric motor speed.
Braking Characteristics: Input data that defines the torque response of
the brake as a function of speed and temperature. The backspin
calculation uses linear interpolation/extrapolation of this data to
determine the magnitude of the applied brake torque at each time-step
of the simulation. Brake torque must be specified at a minimum of two
speeds at each brake temperature. If only one brake temperature is
specified, the torque response will be independent of temperature.
When entering the characteristics of brakes with non-linear
torque/speed/temperature relationships, it is important to ensure that
the brake response will be accurately represented by the linear
interpolation/extrapolation of the data input. Although the program
will extrapolate the brake response over the full range of
speeds/temperatures associated with the calculated backspin response,
the errors associated with extrapolations well beyond the established
brake characteristics can be significant. Therefore, it is important to
obtain brake data covering the full range of the predicted response
from the equipment manufacturer.
Note: Some brake systems can be adjusted so they will continue to
apply a resistive torque when the polish rod backspin speed is zero,
while other brakes will not apply any torque until the brake activation
speed is reached (see below).
Brake Activation Speed: The threshold rotational speed at which the
brake begins to apply resistive torque to inhibit the backspin of the PC
pump system (e.g. centrifugal spring brake). If the brake activates as
soon as the system begins to backspin, this value should be left at
zero.
Dissipation Characteristics: The rate of heat transfer from the brake to
its surroundings. Energy dissipation rates are specified as a function
of differential temperatures (i.e. the difference between the brake
temperature and the ambient temperature) in the corresponding table
input area at the bottom of the window. The program uses linear

interpolation between the specified temperatures to calculate the

energy dissipation rate at each time-step of the simulation. Note that
the program automatically specifies a zero dissipation rate at a
differential temperature of zero (i.e. no heat transfer when the brake
temperature is equal to the ambient temperature).
Brake Specific Heat Capacity: The amount of energy required to raise
the temperature of the brake by one degree. This value is used to
calculate the increase in brake temperature due to the braking action
during the backspin. All braking energy is assumed to go directly into
heating the brake.
Maximum Brake Temperature: The maximum operating temperature
for the brake based on applicable safety requirements or the functional
limits of the system components.
Comments: Any additional information you wish to input concerning
the brake model.
It is important to ensure that the values you input correspond to the units
of measurement that are currently selected.
5. Under the Charts tab, the "Braking Characteristics"
Dissipation" data are displayed in graphical form.

and

"Energy

6. To remove a brake model from a database, select it by highlighting its

name, right-click and select "Delete Model".
Once you have finished, click OK to close the Custom Equipment input
window. All of the new brake models will now be available.

Backspin Calculation Scenarios

Most driveheads are equipped with some type of backspin retarder or brake
system which is used to limit backspin speeds to the allowable speed ratings
of the drivehead and sheave components. However, it is important for
operators to ensure that the brake specifications of the drive equipment they
install are adequate for their specific application conditions under both of the
backspin scenarios described above.

PCPUMP performs backspin calculations for two key shut-down scenarios:

seized pump and normal shutdown. The Seized Pump case models situations
in which the rotor becomes stuck within the stator and the strain energy
stored in the rod string is released without any fluid drainage occurring. The
Normal Shutdown case models system stoppages under normal operating
conditions where the fluid within the tubing drains back into the wellbore
causing the pump, rod string, and drive to spin in reverse. Both cases are
important and should be considered whenever you are designing a new
installation or changing the surface equipment and when production
conditions change significantly.
Seized Pump Scenario
In the seized pump case, the pump stops turning and the torsional strain
energy (twists) stored in the rod string causes the system to start spinning in
the reverse direction until all of the energy has been dissipated. The
response period is generally quite short and little fluid drains from the
production tubing due to the seized pump condition.
At the top of the calculation area, select the Seized Pump scenario to activate
the data inputs for this backspin mode. The following values specific to the
seized pump scenario must be entered before the analysis can be executed:

Initial Brake Temperature: The brake temperature at backspin initiation.

Ambient Temperature: The air temperature during backspin.
Seized Pump Torque: The maximum torque stored in the rod string when
the backspin commences, which will be governed by one of the following
three conditions: (1) rod torque corresponding to motor output torque;
(2) maximum rod torque capacity; or (3) torque corresponding to
controller limits. The seized pump torque represents the amount of
potential energy stored in the rod string that must be dissipated during the
backspin event. Higher torque values generally lead to faster peak speeds
and longer backspin periods.
Note: The stall torque for electric motors without a torque-limiting device
is typically between two and three times the full-load torque. Therefore,
you may wish to be conservative in choosing the value you specify for the
seized pump torque (i.e. enter a value higher than the operating torque).

Normal Shutdown Scenario

In the normal shutdown case, the fluid remaining in the production tubing
drains back to the well through the pump, causing both the pump and drive
system to accelerate backwards. This continues until the fluid energy in the
tubing (i.e. fluid level) is balanced by the fluid column in the annulus and the
pump friction, which can take anywhere from several minutes to hours,
depending on the circumstances.
The inputs for this mode are activated by selecting the Normal Shutdown
scenario at the top of the calculation panel. The following parameters must
be specified before the normal shutdown scenario is analyzed:
Initial Brake Temperature: The brake temperature at backspin initiation.
Ambient Temperature: The air temperature during backspin.
Fluid Level: The fluid level in the tubing/casing annulus (depth from
surface) when the system shuts down. The measurement units for this
parameter can be toggled between mKB, jts (joints), and Vm (vertical
metres).
Pump Speed: The speed at which the pump is operating when the system
shuts down.
Calculation Options
This input area allows you to specify additional conditions governing the
backspin analysis. The last three options are only available if the Normal
Shutdown scenario is selected.

Calculate Sensitivity:

When this check-box is selected, the program will

determine the peak speed, the backspin time and the peak and final brake
temperatures for a range of seized torque values (Seized Pump case) or
fluid levels (Normal Shutdown case).
Driver Sheave/Electric Motor Disengaged (Broken Belts):

When this check-box is

selected, the motor and driver sheave inertia are ignored in the
calculations, although the surface equipment friction will still be included
in the system analysis. This scenario simulates the system in the event of
broken belts.
Brake Disengaged (No Braking Action):

When this check-box is selected, the

program will remove the brake from the analysis, making the surface
equipment friction the only source of energy dissipation within the drive

system. This scenario simulates the system in the event there is no

braking action.
Flowback to Reservoir Above Perforation Pressure:

When this check-box is selected,

the program requires you to specify a flowback pressure at the
perforations. If the fluid pressure at the perforations exceeds this value,
any additional fluid which drains from the tubing is assumed to flow back
into the reservoir. If the pressure is below the specified flowback pressure
or if the option is not selected, all of the fluid draining from the tubing is
assumed to remain in the casing/tubing annulus.
Ignore Flow Considerations During Backspin:

When this check-box is selected, the

program will disregard pressure losses in the fluid as it drains out of the
tubing string.
Ignore Rod/Tubing Friction During Backspin:

When this check-box is selected, the

program will disregard any torsional loading effects associated with contact
between tubing and rod string components during backspin.

Backspin Analysis Results

Clicking the Calculate button will commence the backspin calculation for the
active scenario.

Backspin Results - Summary Output Window

Results of the backspin analysis are displayed on the Summary tab and in
accompanying charts. Results presented on the Summary tab are as follows:
Peak Electric Motor - Speed: The highest rotational speed reached by the
electric motor during the backspin response.
Peak Sheaves - Speed: The highest rotational speed reached by each
sheave during the backspin period.
Peak Sheaves - Velocity: The highest speed reached at the outside
diameter of each sheave during the backspin period.
Peak Rod String - Speed: The highest polish rod speed predicted during
the backspin response.

Backspin Time: The time period from backspin initiation to the point when
the polish rod stops moving. The toggle button allows the time to be
displayed in seconds or minutes.
Retained Torque: The magnitude of the torque remaining (if any) in the
rod string after the polish rod has stopped moving.
Backspin Revolutions: The cumulative number of polish rod revolutions
over the entire backspin period. (Normal Shutdown case only).
Backspin Fluid Drain: The volume of fluid which has drained from the
production tubing during the backspin period. (Normal Shutdown case
only).
Braking Energy: The total amount of energy dissipated by the brake.
Total Energy Dissipated: The total amount of energy dissipated by the
system during the backspin period, including braking energy and frictional
losses.
Brake Temperatures: The peak and final temperatures of the brake.
Final Fluid Levels (from surface): The fluid levels in the Tubing and Casing
when the polish rod has stopped moving. (Normal Shutdown case only).
The following tabs display the corresponding backspin analysis output charts:
Backspin Response: Displays the polish rod torque and speed and the total
system energy as a function of time. A numeric value for the total amount
of energy dissipated is also displayed.
Fluid Level Response: Displays the casing and tubing fluid levels and the
hydraulic torque generated by the pump as a function of time. The
retained (final) torque, the total volume of fluid drained from the tubing,
and the cumulative number of rod rotations during the backspin are also
displayed on the chart. (Normal Shutdown case only).
Braking Response: Displays the applied braking torque, the brake
temperature, and the polish rod speed as a function of time. The total
amount of energy dissipated by the brake and the peak temperature are
also displayed.
Sensitivity - Peak Speed: Displays the peak backspin speed as a function of
seized pump torque (Seized Pump case) or fluid level (Normal Shutdown
case).
Sensitivity - Time and Temperatures: Displays the backspin time period
and the peak and final temperatures of the brake as a function of seized
pump torque (Seized Pump case) or fluid level (Normal Shutdown case).

Technical Considerations

The following factors affect the backspin response of a surface driven PC

pumping system:

Surface Equipment Friction: Friction in the rotating surface equipment

acts to slow the system down during the backspin.
Drive System Inertia: The nature of the backspin response is partially
governed by the mass moment of inertia of the sheaves, motor and gear
box. Systems with high mass moment of inertia values accelerate more
slowly than low-inertia systems. Most of the inertia in a PC pump drive is
concentrated in the driven (large) sheave and the electric motor.
Brake Response: The amount of torque applied by the brake system as a
function of both speed and brake temperature. The maximum backspin
speed and the duration of the backspin period both depend on the brake
response.
Brake Characteristics: Several different brake characteristics affect the
backspin response of the system. In addition to the brake response
(described above), the location within the drive system, heat capacity,
activation speed, and energy dissipation characteristics of the brake, as
well as the maximum allowable brake temperature, contribute to system
performance. For several of the brake system designs in current use, the
temperature of the brake plays an important role (especially in the normal
shutdown scenario) because it governs the amount of braking torque
provided at different speeds. In addition, proper drive selection and
performance is important to ensure that the temperature limits imposed by
wellhead operating environment regulations and by the functional limits of
the mechanical components in the system are not exceeded under worst
case conditions.
Seized Pump Torque: The maximum torque stored in the rod string
when the backspin commences, which will be governed by one of the
following three conditions: (1) rod torque corresponding to motor output
torque; (2) maximum rod torque capacity; or (3) torque corresponding to
controller limits. The seized pump torque represents the amount of
potential energy stored in the rod string that must be dissipated during the
backspin event. Higher torque values generally lead to faster peak speeds
and longer backspin periods.

Rod String/Tubing Properties: In the seized pump case, the rod string
diameter, shear modulus, and length contribute to the stiffness of the
system. The same is true in the normal shutdown case, but the rod string
configuration also affects the amount and dissipation of stored fluid energy
by influencing the fluid volume within the tubing and contributing to the
flow losses that occur when the fluid drains back to the wellbore through
the pump.
Tubing and Casing Fluid Levels and Fluid Densities (Normal
Shutdown case only): The differences between the levels and average
densities of the fluid columns within the tubing and the casing/tubing
annuli define the differential pressure that exists across the PC pump
throughout the backspin period (i.e. the backspin driving force). The fluid
level in the tubing is generally assumed to start at 0 mKB (i.e. surface),
although additional flow line and tank volumes may also drain back to the
well in some cases. The initial casing fluid level is assumed to be the
operating fluid level.
Pump Displacement (Normal Shutdown case only): The nominal
displacement of the PC pump. High displacement pumps produce more
hydraulic torque than low displacement pumps at a given pump differential
pressure. In the normal shutdown case, this is important because it
dictates the amount of driving torque produced by the fluid column within
the tubing.
Pump Friction Torque (Normal Shutdown case only): Torque required to
overcome the mechanical rotor/stator friction as well as hydraulic losses
within the pump. Friction torque acts against the direction of rotation and
therefore serves to dissipate energy and slow the system down during
backspin.
Pump Volumetric Efficiency (Normal Shutdown case only): The ratio of
the flow rate under normal operating conditions to the flow rate calculated
based on the nominal displacement and speed of the pump. A constant
pump efficiency is used in the backspin analyses.
Fluid Properties (Normal Shutdown case only): The density of the fluid
in the tubing and wellbore affects the pump differential pressure as noted
above. The viscosity of the produced fluid also impacts backspin response

by controlling the amount of energy dissipation that occurs due to flow

losses in the tubing and in the casing/tubing annulus.

Warning: it is important to recognize that the results predicted by PCPUMP

provide no guarantee against the occurrence of an uncontrolled backspin
event or sheave failure.

Related Topics
Analysis Results
Using Tables and Charts
Printing Reports
Exporting Data

You are here: Analysis Results Windows > Auxilliary Analysis Windows > Sand Settling Velocity

Sand Settling
When sand is produced by the well, the tubing flow velocity must be
significantly larger than the sand particles settling velocity to ensure that the
sand can be carried successfully to surface by the flow.
The Sand Settling tab can be accessed within the Auxiliary Analysis window, or
by clicking Tools in the PCPUMP toolbar and selecting "Sand Settling Model".
The Sand Settling window is shown below:

Sand Settling Window

If you have just completed a single-phase calculation, PCPUMP will

automatically display the available information. If advanced viscosity is used,
the lowest viscosity in the tubing string will be used.

Sand Settling Specification

Note: This model was developed for single-phase flow only. As well, this
model does not consider the interaction between sand particles, so the results
will be less accurate in high sand cuts.
The following values must be entered prior to performing a sand settling
calculation:
Fluid Viscosity: The viscosity of the produced fluid.
Fluid Density: The density of the produced fluid.
Note: The fluid density passed by PCPUMP will include the effect of any
sand (calculated in the Fluid Properties tab), so you should adjust the
value accordingly if you have a high sand cut.
Particle Density: The density of the sand particles.
Particle Diameter: The average diameter of the sand particles.
Once the above information has been entered, the terminal velocity of the
particle and the minimum velocity of the fluid will be calculated.

Sand Settling Velocity: The velocity at which the sand particle will fall in
the specified fluid.
Minimum Fluid Velocity in Tubing: The minimum velocity of the produced
fluid.
If the minimum velocity of the produced fluid is significantly higher than the
terminal velocity of the particle, then it can be assumed that the particles will
be carried to surface.

Technical Discussion
PCPUMP uses the following equation to calculate the sand settling velocity:
v = [(4 P D g)/(3 f CD)]0.5
Where:
v is the settling velocity (m/s)
P is the difference in density between the particle and the fluid (kg/m)
D is the particle diameter (m)
g is 9.81 m/s
f is the density of the fluid (kg/m)
CD is the drag coefficient, a function of Reynolds number

Related Topics
Analysis Results
Using Tables and
Charts
Printing Reports
Exporting Data

You are here: Help/Troubleshooting > Introduction

Help/Troubleshooting
The previous sections of this Help File described the layout and use of
PCPUMP. As you venture beyond the scope of this Guide and use the program
to evaluate your own applications, you may occasionally encounter problems.
This Help/Troubleshooting part of the Help File may assist you in resolving
these problems. In addition, further troubleshooting information is available
on CFER's PCPUMP web site at http://www.PCPUMP.com.

Related Topics
Input Restrictions

You are here: Help/Troubleshooting > Input Restrictions

Input Restrictions
PCPUMP requires numerous inputs. In most cases, restrictions or limits are
placed on these inputs for one of the following reasons:
to avoid computational errors;
to prevent correlations from being used outside their valid range; and
to warn the user of incorrectly entered values

Analysis Calculation Messages Window

This window displays a message which informs the user of the problem input
parameter and its valid entry range. To return back to the program, click the
Close button.
Then correct the invalid input value before proceeding with
further data input or the execution of a calculation. If you do not correct the
input, an error message will likely be generated during the calculation
process.
Note that there are also some ranges which apply to calculated values within
PCPUMP. PCPUMP will normally not abort a calculation if one of these ranges is
exceeded, but will display a warning message in the Analysis Calculation
Messages window which appears at the end of an analysis calculation.
The seven tables below list the valid range of values for input parameters in
the different areas of PCPUMP.
Preferences:
Location

Input Parameter

Valid Range

Default
Values

Pump Friction (Static)

x 0 Nm

Default
Values

Volumetric Efficiency
(Static)

0% x
100%

Default
Values

Gas Specific Gravity

0.55 x
1.20

Default
Values

Water Specific Gravity

1.00 x
2.00

Default
Values

Sand Specific Gravity

2.00 x
4.00

Default
Values

Tubing Roughness

0.001 mm
x 2 mm

Default
Values

Free Gas Separation

0% x
100%

Default
Values

Supply Frequency

x > 0 Hz

Default
Values

Supply Voltage

x>0V

Default
Values

Power Cost

x > 0 $/kWh

Default
Values

Gas Specific Heat

x>0
kJ/kgK

Wellbore Geometry:
Location

Input
Parameter

Valid
Range

Well Design Mode

Initial Hole
Angle

0 x
90

Well Design Mode

Initial
Azimuth

0 x
360

System Configuration:
Location

Input Parameter

Valid Range

Main

Pump Seating

x > 0 mKB

Main

Mid-Perforations

x > 0 mKB

Pump Selection

Pump Friction
(Static)

x 0 Nm

Pump Selection

Volumetric
Efficiency (Static)

0% x
100%

Pump Selection: Pump

Test Information

Target Pump Speed

x > 0 RPM

Pump Selection: Pump

Test Information

Target Differential
Pressure

x > 0 kPa

Pump Selection: Custom

Pump

Nominal Pump
Displacement

x>0
m /D/RPM
3

Pump Selection: Custom

Pump

Pump Pressure
Rating

x > 0 kPa

Pump Selection: Custom

Pump

Pump Length

x>0m

Pump Selection: Custom

Pump

Pump Outside
Diameter

x > 0 mm

Pump Selection: Custom

Pump

Minor Rotor
Diameter

x > 0 mm

Pump Selection: Custom

Pump

Pump Eccentricity

x > 0 mm

Pump Selection: Custom

Pump

Rotor Pitch

x > 0 mm

Casing/Tubing/Tail
Joint/Shroud Selection

Tubing/Casing/Tail
Joint Length

x>0m

Casing/Tubing/Tail
Joint/Shroud Selection

Tubing Coupling
Diameter

x > tubing OD

Casing/Tubing/Tail
Joint/Shroud Selection

Shroud OD

x > 0 mm

Casing/Tubing/Tail
Joint/Shroud Selection

Shroud ID

0 mm < x <
shroud OD

Rod String Selection

Length

0.5 m x 25
m

Rod String Selection

No. Guides

1 x 10

Rod String Selection

Rods/Length

X>0

Rod String Selection:

Rod Guide Optimization

Maximum Contact
Load

x>0N

Rod String Selection:

Rod Guide Optimization

Minimum No. Rod

Guides

1 x 10

Rod String Selection:

Rod Guide Optimization

Maximum No. Rod

Guides

1 x 10

Surface Drive Equipment

Selection: Belts

Reduction Ratio

X>0

Surface Drive Equipment

Selection: Belts

Power Transmission
Efficiency

0% < x
100%

Surface Drive Equipment

Selection: Prime Mover

Motor Power Rating

3 kW < x
125kW

Surface Drive Equipment

Selection: Prime Mover

Motor Poles

2x8

Surface Drive Equipment

Selection: Prime Mover

Motor Efficiency
(Nominal)

0% < x
100%

Surface Drive Equipment

Selection: Prime Mover

Motor Power Factor

(Nominal)

0<x1

Surface Drive Equipment

Selection: Prime Mover

Supply Frequency

x > 0 Hz

Surface Drive Equipment

Selection: Prime Mover

Supply Voltage

x>0V

Downhole Drive
Equipment Selection:
Motor

Efficiency (static)

0% < x
100%

Downhole Drive
Equipment Selection:
Motor

Power Factor
(static)

0< x 1

Downhole Drive
Equipment Selection:
Motor

Slip (static)

x 0 RPM

Downhole Drive
Equipment Selection:
Motor

Temperature Rise
(static)

x 0 C

Custom Drive Assembly

Power Requirement

x > 0 kW

Custom Drive Assembly

Max. Thrust Load

x > 0 kN

Custom Drive Assembly

Max. Speed

x > 0 RPM

Custom Drive Assembly

Max. Power

x > 0 kW

Custom Drive Assembly

Max. Torque

x > 0 Nm

Custom Drive Assembly

Length

x>0m

Custom Drive Assembly

Gear Reduction

x>0

Custom Drive Assembly

Outside Diameter

x > 0 mm

Custom Motor

Outside Diameter

x > 0 mm

Custom Motor

Length

x>0m

Custom Motor

Number of Poles

x>0

Custom Motor

Power Rating

x > 0 kW

Custom Motor

Max. Winding
Temp.

x > 0 C

Custom Motor

Nameplate
Frequency

x > 0 Hz

Custom Motor

Nameplate Voltage

x>0V

Custom Motor

Nameplate Current

x>0A

Custom Cable

Size

x>0

Custom Cable

Thickness

x > 0 mm

Custom Cable

Max. Conductor
Temp.

x > 0 C

Motor Test

Motor Load

x>0%

Motor Test

Efficiency

x>0%

Motor Test

Power Factor

x>0

Motor Test

Motor Speed

x > 0 RPM

Motor Test

Temperature Rise

x > 0 C

Motor Test

Test Frequency

x > 0 Hz

Cable Ampacity Curve

Input

Reference
Conductor
Temperature

x > 0 C

Cable Ampacity Curve

Input

Current

x>0A

Cable Ampacity Curve

Input

Voltage Drop

x>0V

Cable Ampacity Curve

Input

Conductor
Temperature

x > 0 C

Cable Ampacity Curve

Input

Ambient
Temperature

x > 0 C

Fluid Properties:
Location

Input Parameter

Valid Range

Single-Phase

Fluid Density
Tubing

x > 0 kg/m3

Single-Phase

Fluid Density
Casing

x > 0 kg/m3

Single-Phase

Gas Specific
Gravity

0.55 x 1.20

Single-Phase

Water Cut

0% x 100%

Single-Phase

Sand Cut

0% x 100%

Single-Phase

Fluid Viscosity

x > 0 cp

Single-Phase w/Fluid
Composition

Oil API Gravity

0 x 150

Single-Phase w/Fluid
Composition

Water Specific
Gravity

1.00 x 2.00

Single-Phase w/Fluid

Sand Specific

2.00 x 4.00

Composition

Gravity

Single-Phase w/Fluid
Composition

Tubing Density
Factor

0x2

Single-Phase w/Fluid
Composition

Casing Density
Factor

0x2

Multiphase

Oil API Gravity

15 x 150

Multiphase

Gas Specific
Gravity

0.55 x 1.20

Multiphase

Water Salinity

0 ppm x
2.5e5 ppm

Multiphase

Producing GOR

x > 0 m3/m3

Multiphase

BS&W content

0% x 100%

Multiphase

Free Gas
Separation

0% x 100%

Advanced Viscosity
BS&W Effects

Oil Viscosity

x > 0 cp

Advanced Viscosity
BS&W Effects

Max. Viscosity
Factor

x>1

Advanced Viscosity
BS&W Effects

Inversion Fraction

0<x<1

Advanced Viscosity
Temperature Effects

Viscosity

x > 0 cp

Advanced Viscosity
Temperature Effects

Temperature

x > -40C

Advanced Viscosity
Non-Newtonian Effects

Viscosity

x > 0 cp

Advanced Viscosity
Non-Newtonian Effects

Shear Rate

x > 0 1/s

Fluid Thermal Properties

Fluid Cp

x > 0 kJ/kgK

Fluid Thermal Properties

Fluid K

x > 0 W/mK

Fluid Thermal Properties

Oil Cp

x > 0 kJ/kgK

Fluid Thermal Properties

Oil K

x > 0 W/mK

Fluid Thermal Properties

BS&W Cp

x > 0 kJ/kgK

Fluid Thermal Properties

BS&W K

x > 0 W/mK

Operating Conditions:

Location

Input Parameter

Valid Range

Operating Conditions

Fluid Rate

x > 0 m3/D

Operating Conditions

Pump Speed

x > 0 RPM

Operating Conditions

Motor Operating
Frequency

x > 0 Hz

Operating Conditions

Fluid Level

x0m

Operating Conditions

Bottomhole
Pressure

x 0 kPa

Operating Conditions

Tubing Head
Pressure

x 0 kPa

Operating Conditions

Casing Head
Pressure

x 0 kPa

Operating Conditions

Bottomhole
Temperature

-10C x
200C

Operating Conditions

Temperature
Gradient

x 0 C/100m

IPR Data:
Location

Input Parameter

Valid
Range

IPR Data

Static Reservoir
Pressure

x > 0 kPa

IPR Data

Bubble Point Pressure

x 0 kPa

IPR Data

Test Point Producing

Pressure

x > 0 kPa

IPR Data

Test Point Fluid Rate

x>0
m3/D

IPR Data

Test Point BS&W Content

x > 100%

IPR Data

Target Producing
Pressure

x 0 kPa

IPR Data

Target Fluid Rate

x0
m3/D

Calculation Modes:

Location

Input Parameter

Valid
Range

Pump Comparison
Configuration

Minimum Pump Speed

x 0 RPM

Pump Comparison
Configuration

Maximum Pump Speed

x 2500
RPM

Pump Comparison
Configuration

Minimum Pump
Pressure Rating

x 0 %Rtd

Pump Comparison
Configuration

Maximum Pump
Pressure Rating

x 500
%Rtd

Batch Comparison
Configuration

Fluid Level

x0m

Batch Comparison
Configuration

Fluid Rate

x > 0 m3/D

Batch Comparison
Configuration

Bottomhole Pressure

x 0 kPa

Batch Comparison
Configuration

Pump Speed

x > 0 RPM

Batch Comparison
Configuration

Motor Operating
Frequency

x > 0 Hz

Related Topics
Help/Troubleshooting

You are here: Help/Troubleshooting > License Troubleshooting

Licence Troubleshooting
This Help File will assist in resolving licensing issues with PCPUMP. It captures
common problems that arise when installing the software, and
activating/upgrading the licence security key (HASP/Hardlock).
If you have any further questions, or if you are unable to resolve your problem
with the information provided below, please email the PC-PUMPTechnical
Support at pcpump@cfertech.com for more information.

HASP/Hardlock Needs to be upgraded [1->43]

A common licensing issue that can occur is needing to activate or upgrade
your Hardlock or HASP. If this is the case, you will get a Security window that
looks something like the screenshots below:
When using a HASP, the window will look like this:

Security Window - HASP Needs Features Upgraded

When you get this window, click the

Add/Upgrade Features window:

Upgrade

button and you will see the

Add/Upgrade Features Window - HASP Needs Features Upgraded

When using a Hardlock, the window will look like this:

Security Window - Hardlock Needs Features Upgraded

When you get this window, click the

Add/Upgrade Features window:

Upgrade

button and you will see the

Add/Upgrade Features Window - Hardlock Needs Features Upgraded

If your company is subscribed to the current PCPUMP Maintenance Plan, you

are eligible to run the most up-to-date version of PCPUMP. In this case, please
contact PCPUMPTechnical Support at CFER to request the feature codes to
upgrade your Hardlock/HASP. Each program feature is assigned a numerical
code that CFER will provide along with an alphanumeric code that will serve
as a verification "key". Keep a record of the feature code and the verification
key code.
To request your feature codes, please email the PC-PUMPTechnical Support at
pcpump@cfertech.com, or click on "Click here for PC-PUMP Technical Support" in
the Security window. Technical Support will need your HASP or Hardlock serial
number (from the Security window) in order to provide the correct feature
codes.

PC-PUMP Support Window - Requesting Feature Codes

HASP: Feature not found/HARDLOCK: Licence

container not found
When PCPUMP is unable to locate your licence security key (either HASP or
Hardlock), the Security window and Add/Upgrade Features window appear as
follows:

Security Window - No Licence Found

Add/Upgrade Features Window - No Licence Found

Since HASPs and Hardlocks come in either "stand-alone" or "network"

varieties, the steps to resolve this problem will differ depending on your
licence. Instructions are provided below for stand-alone HASPs, network
HASPs, stand-alone Hardlocks, and network Hardlocks.

Stand-alone HASPs
Running PCPUMP with a stand-alone HASP requires that the device be plugged
directly into the USB port of the computer that is running PCPUMP. The
following steps summarize typical troubleshooting to get your software
running:
i. When plugged into your USB port, the HASP drivers will install on your
computer. Once this is complete, a red light should be clearly visible on
your stand-alone HASP. If this red light is not on, remove the HASP and
plug it back into the USB port or another USB port on you computer. If the
red light is not on, close PC-PUMP and restart the program. If the red light is
still not visible after waiting 1-2 minutes for the drivers to install, please
contact PCPUMPTechnical Support.
ii. Next, try updating your environment variables to ensure that PCPUMP
looks for the HASP on your USB port. In your Control Panel, select
"System" then "Advanced system settings" and click "Environment
Variables". Under "User variables for *USERNAME*", click New. Enter the
variable name as "HL_Search" and variable value as "USB". Press OK.
Close and restart PCPUMP.

Windows Environment Variables Entry

iii. If the steps above don't resolve the problem, uninstall PCPUMP, redownload
from
http://www.pc-pump.com/pc-pump-software/currentversion, and re-install the software.
iv. If the problem still is not resolved, please contact PCPUMPTechnical Support
for more information.

Network HASPs
Running PCPUMP with a network HASP requires that the device be plugged into
a server on your network. The following steps summarize typical
troubleshooting to get your software running:
i. Verify that your HASP is visible on the network by going to the Sentinel
HASP Admin Control Center at http://localhost:1947 and clicking "Sentinel
Keys". You should see a list of available licences similar to below. If a
HASP is visible in the Sentinel Keys table, it has been detected and is

ready to use.

Sentinel Admin Control Center - Sentinel Keys Table

ii. If the licence is not visible and PC-PUMP is on a different sub-net on your
network from your computer, open the Sentinel HASP Admin Control
Center at http://localhost:1947 and click "Configuration". Next, click the
"Access to Remote License Managers" tab to configure your network
settings as follows:
Allow
Access to
Remote
Licenses

Enables your machine to search for remote Sentinel License Managers

on the local network. When you allow access to remote licences, you
must either select "Broadcast Search for Remote Licenses", specify IP
addresses in the "Specify Search Parameters" area, or both. This
option should be checked.

Broadcast
Search for
Remote
Licenses

Enables your machine to search for remote Sentinel License Managers

on the local network via broadcasts. This option should be
checked.

Aggressive
Search for
Remote
Licenses

Aggressive searching reduces the update frequency of remote Sentinel

information and enables your machine to connect to remote Sentinel
License Managers, even though they cannot be detected using UDP
datagram search methods. Note that this option may enable firewalls
to be transversed. This option does not need to be checked.
Defines the specific machines that may be searched by this machine
for remote Sentinel License Managers.

Specify
Search
Parameters

Specify data as IP addresses (for example, 10.1.1.17), Broadcast

addresses (for example, 10.1.1.255), or machine names (for
example, hklm001.ecomp.com)
When using the IPv6 protocol, use the IPv6 address format. For
example, type FF02::1 to access all remote Sentinel License
Managers that are part of the default local group defined in the
IPv6 subnet.
Each entry must be on a separate line. This option may be
necessary to locate licences on servers.

iii. Network HASPs have a limited number of seats depending on how many

were purchased for that licence. To verify if any seats are available on the
network, go to the Sentinel HASP Admin Control Center at
http://localhost:1947 and click "Features". Under the "Login" column you
will see the number of seats currently being accessed and under the
"Limit" column you will see the total number of seat on the HASP. If there
are no seats available, you will need to wait until one is free or request
that a seat be freed up on the network. If seats are frequently full on your
HASP, you may consider contacting C-FER to purchase additional seats.

Sentinel Admin Control Center - HASP Features Table

iv. Ensure that there is no firewall software blocking the communications

between the PC-PUMP program and the Hardlock server. This can be quickly
checked by disabling the firewall software and trying PC-PUMP. It may be
necessary to create the appropriate firewall rules to allow this
communication. PC-PUMP communicates using UDP port 3047.
v. If the problem is still not resolved, please contact PCPUMPTechnical Support
for more information or click the "Help" button on the bottom right of the
Sentinel HASP Manager Admin Control Center at any time for context
sensitive help.

Stand-Alone Hardlocks
Running PCPUMP with a stand-alone Hardlock requires that the device be
plugged directly into the USB port of the computer that is running PCPUMP.
The following steps summarize typical troubleshooting to get your software
running:
i. When plugged into your USB port, the Hardlock drivers will install on your
computer. Once this is complete, a red light should be clearly visible on
your stand-alone Hardlock. If this red light is not on, remove the Hardlock
and plug it back into the USB port or another USB port on you computer. If
the red light is not on, close PC-PUMP and restart the program. If the red
light is still not visible after waiting 1-2 minutes for the drivers to install,
please contact PCPUMP Technical Support.
ii. Next, try updating your environment variables to ensure that PCPUMP
looks for the Hardlock on your USB port. In your Control Panel, select
"System" then "Advanced system settings" and click "Environment
Variables". Under "User variables for *USERNAME*", click New. Enter the

following environment variables then press OK and close and restart

PCPUMP:

Variable name "HL_Search" and Variable value "USB"

Variable name "HL_WAIT" and Variable value "5000"

Windows Environment Variables Entry

iii. If the steps above don't resolve the problem, uninstall PCPUMP, redownload
from
http://www.pc-pump.com/pc-pump-software/currentversion, and re-install the software.
iv. If the problem still is not resolved, please contact PCPUMPTechnical Support
for more information.

Network Hardlocks
Running PCPUMP with a network Hardlock requires that the device be plugged
into a server on your network. The following steps summarize typical
troubleshooting to get your software running:
i. Verify that your licence is visible on the network by installing Aladdin
Monitor.
Aladdin
can
be
downloaded
from
ftp://ftp.aladdin.com/pub/aladdin.de/hardlock/aksmon.zip.
Install
this
program locally to your computer, and it will show the available servers
that are hosting a Hardlock on the left hand side of its main window. If a
Hardlock is visible in the Hardlock Server table, it has been detected and is
ready to use.

Aladdin Monitor - Hardlock Server Screen

ii. If the network Hardlock is on a different sub-net on your network from the
computer you are using to run PC-PUMP, PC-PUMP may not be able to locate
the Hardlock without special instructions. In your Control Panel, select
"System" then "Advanced system settings" and click "Environment
Variables". Under "User variables for *USERNAME*", click New. Enter the

following environment variables then press OK and close and restart

PCPUMP:
SET HL_SEARCH=IP
SET HLS_IPADDR=<ip address of server>
SET HLS_WAIT=5000
If your company has more than one network Hardlock for PC-PUMP, you can
enter the IP addresses of multiple servers, separated by commas. PC-PUMP
will attempt to use them in order (i.e., it will try the server listed first, and
move on to subsequent servers only if the first one is unavailable).
iii. Network Hardlocks have a limited number of seats depending on how
many were purchased for that licence. To verify if any seats are available
on the network, go to Aladdin Monitor Hardlock Server. The "Max Logins"
column shows the total number of seats on the Hardlock, and the Current
column shows the number of seats that are currently taken. If there are
no seats available, you will need to wait until one is free or request that a
seat be freed up on the network. If seats are frequently full on your
Hardlock, you may consider contacting C-FER to purchase additional seats.

Aladdin Monitor - Hardlock Server Screen

iv. Ensure that there is no firewall software blocking the communications

between the PC-PUMP program and the Hardlock server. This can be quickly
checked by disabling the firewall software and trying PC-PUMP. It may be
necessary to create the appropriate firewall rules to allow this
communication. PC-PUMP communicates using UDP port 3047.
v. If the problem still is not resolved, please contact PCPUMP Technical
Support for more information.
If this help page did not contain the solution to your problem, or if you have
any other questions about PC-PUMP please contact C-FER at (780) 450-3300 or
at pcpump@cfertech.com.

You are here: Help/Troubleshooting > Errors > Error Message: "Fluid level must be above the mid
perforations"

Error Message: "Fluid level must be above the

mid perforations"
This help page summarizes the known causes of the error message "Fluid level
must be above the mid perforations" and identifies steps to follow to avoid the
error. If this page does not contain applicable steps to avoid this error, please
contact PCPUMP Technical Support for assistance. C-FER will continually work to
update this help page to include new reasons for PCPUMP encountering the
error.
Always begin the troubleshooting of an error by ensuring that all inputs in the
Wellbore Geometry, Equipment Configuration, Fluid Properties and Operating
Conditions tabs are correct.
This error occurs in PCPUMP when the Fluid Level is below the perforations and
an IPR and/or Bottomhole Pressure is specified. The following list summarizes
the design scenarios which result in this error, and recommended changes to
the design to prevent this error from being generated:
1. The Fluid Level is below the Mid-Perforations Depth and an IPR is specified:
Conditions

The Fluid Level is below the Mid-Perforations Depth, and an IPR is

specified in the Operating Conditions tab.

Result

Inflow Performance Relationships in PCPUMP are not intended for use

when the Fluid Level is below the perforations. The results may be
invalid, so PCPUMP shows an error message.
Increase the height of the annular fluid column above the perforations
by doing the following in the Operating Conditions tab:

Remedial
Action

Fluid Level: Decrease;

Submergence (measured): Increase; or
Bottomhole Pressure: Increase.
Once the Fluid Level is above the perforations, the PCPUMP calculation
can proceed.

Deactivate the Specify IPR data option and specify Operating Information
inputs in the Operating Conditions tab. Instead of an IPR, the following
must be provided:
Produced Fluid Flow Rate (surface);

Alternative
Remedial
Action 1

Pump Speed; or
Motor Operating Frequency (For ESPSP cases).
And:
Fluid Level; or
Submergence (measured).
Once the Specify IPR data option is deactivated, the PCPUMP calculation
can proceed until the Fluid Level is below the pump intake or tailjoint,
or until there is a negative pressure at the intake due to flow losses in
the tailjoint (whichever occurs first).

2. The Fluid Level is below the Mid-Perforations Depth and a Bottomhole

Pressure is specified:
Conditions

The Fluid Level is below the Mid-Perforations Depth, and a Bottomhole

Pressure is specified in the Operating Conditions tab.

Result

The Bottomhole Pressure at the Mid-Perforations Depth cannot be

used to determine the Fluid Level when the Fluid Level is between the
Mid-Perforations Depth and pump or tailjoint intake, so PCPUMP shows
an error message.

Remedial
Action

Increase the height of the annular fluid column above the perforations
by increasing the Bottomhole Pressure in the Operating Conditions
tab. Once the calculated Fluid Level is above the perforations, the
PCPUMP calculation can proceed.

Alternative
Remedial
Action 1

Specify a Fluid Level or Submergence (measured) in the Operating

Conditions tab. Once this is done, the PCPUMP calculation can proceed
until the Fluid Level is below the pump intake or tailjoint, or until there
is a negative pressure at the intake due to flow losses in the tailjoint
(whichever occurs first).

You are here: Help/Troubleshooting > Errors > Error Message: "Target producing pressure is too high for
the existing configuration"

Error Message: "Target producing pressure is too

high for the existing configuration"
This help page summarizes the known causes of the error message "Target
producing pressure is too high for the existing configuration" and identifies
steps to follow to avoid the error. If this page does not contain applicable steps
to avoid this error, please contact PCPUMP Technical Support for assistance. CFER will continually work to update this help page to include new reasons for
PC-PUMP encountering the error.
Always begin the troubleshooting of an error by ensuring that all inputs in the
Wellbore Geometry, Equipment Configuration,Fluid Properties and Operating
Conditionstabs are correct.
This error occurs in PCPUMP when the fluid level required to achieve the input
or calculated bottomhole pressure is too high (i.e above ground). The following
list summarizes the design scenarios which result in this error, and
recommended changes to the design to prevent this error from being
generated:
1. High gas rate up casing:

Conditions

A Multiphase fluid is selected with high Producing GLR or Producing GOR

in the Fluid Properties tab. There is a large quantity of gas flowing up
the annulus.

Result

At the given input conditions, liquid and gas is flowing up the casing.
While this can be achieved physically, PC-PUMP does not handle this
situation.

Remedial
Action

The pump pressure loading, pump torque, and rod loading can still be
analyzed in a case where fluid would be flowing up the annulus by
increasing the Casing Head Pressure in the Operating Conditions tab.
This will "push" the fluid level back below surface so fluid is not flowing
up the casing in PC-PUMP. Note that the total fluid rate in reality could be
higher than what is calculated in PC-PUMP using this workaround because
PC-PUMP does not consider the fluid flowing up the casing. Also, the fluid
level and submergence provided in the analysis results will not be valid
when increasing the Casing Head Pressure to remove this error.

You are here: Help/Troubleshooting > Errors > Error Message: "Target fluid flow rate results in a producing
pressure is too high for the existing configuration"

Error Message: "Target fluid flow rate results in a

producing pressure that is too high for the
existing configuration"
This help page summarizes the known causes of the error message "Target
fluid flow rate results in a producing pressure that is too high for the existing
configuration" and identifies steps to follow to avoid the error. If this page does
not contain applicable steps to avoid this error, please contact PCPUMP
Technical Support for assistance. C-FER will continually work to update this
help page to include new reasons for PC-PUMP encountering the error.
Always begin the troubleshooting of an error by ensuring that all inputs in the
Wellbore Geometry, Equipment Configuration,Fluid Properties and Operating
Conditionstabs are correct.
This error occurs in PCPUMP when the fluid level required to achieve the input
or calculated bottomhole pressure is too high (i.e above ground). The following
list summarizes the design scenarios which result in this error, and
recommended changes to the design to prevent this error from being
generated:
1. High gas rate up casing:

Conditions

A Multiphase fluid is selected with high Producing GLR or Producing GOR

in the Fluid Properties tab. There is a large quantity of gas flowing up
the annulus.

Result

At the given input conditions, liquid and gas is flowing up the casing.
While this can be achieved physically, PC-PUMP does not handle this
situation.

Remedial
Action

The pump pressure loading, pump torque, and rod loading can still be
analyzed in a case where fluid would be flowing up the annulus by
increasing the Casing Head Pressure in the Operating Conditions tab.
This will "push" the fluid level back below surface so fluid is not flowing
up the casing in PC-PUMP. Note that the total fluid rate in reality could be
higher than what is calculated in PC-PUMP using this workaround because
PC-PUMP does not consider the fluid flowing up the casing. Also, the fluid
level and submergence provided in the analysis results will not be valid
when increasing the Casing Head Pressure to remove this error.

You are here: Help/Troubleshooting > Errors > Error Message: "Pressure out of range. Aborting calculation"

Error Message: "Pressure out of range. Aborting

calculation"
This help page summarizes the known causes of the error message "Pressure
out of range. Aborting calculation" and identifies steps to follow to avoid the
error. If this page does not contain applicable steps to avoid this error, please
contact PCPUMP Technical Support for assistance. C-FER will continually work
to update this help page to include new reasons for PC-PUMP encountering the
error.
Always begin the troubleshooting of an error by ensuring that all inputs in the
Wellbore Geometry, Equipment Configuration,Fluid Properties and Operating
Conditionstabs are correct.
This error occurs in PCPUMP when a calculated pressure conflicts with inputs
provided in other parts of the program. The following list summarizes the
design scenarios which result in this error, and recommended changes to the
design to prevent this error from being generated:
1. There is a negative pressure in the annulus between the perforations and
the pump intake:

Conditions

The pump intake (or tailjoint) is below the Mid-Perforations Measured

Depth, and there is low clearance between the outside diameter of the
tubing, tail joint and/or pump and the casing drift diameter (check the
Equipment Configuration tab). There may also be a low Oil API Gravity
and/or high Total Fluid Viscosity in the Fluid Properties tab. There are
high flow losses in the casing/tubing or casing/tail joint annulus.

Result

Fluid is unable to reach the pump intake for the given Operating
Conditions due to friction losses.

Remedial
Action

Increase the clearance between the casing and tubing. To do so, select
a smaller diameter tubing, tail joint and/or pump in the Equipment
Configuration tab.

The operating conditions can also be changed to help overcome the

losses in the annulus. The user may do so by manipulating the following
parameters as applicable in the Operating Conditions tab:
Alternative
Remedial
Action 1

Produced Fluid Flow Rate (surface): Decrease;

Pump Speed: Decrease;
Motor Operating Frequency: Decrease;

Fluid Level: Decrease (i.e. fluid closer to surface);

Submergence (measured): Increase (i.e. fluid closer to surface);
or
Bottomhole Pressure: Increase.

Alternative
Remedial
Action 2

If for some reason the clearance in the casing/tubing annulus cannot be

increased (such as restrictions in the wellbore geometry), diluent
injection down the casing could be used to reduce the flow losses in the
annulus. C-FER recommends considering increasing the clearance as
much as possible and looking at the Operating Conditions before
considering this option.
For more information, see the Diluent Injection Fluid Properties and
Diluent Injection Tubing Selection help page.

2. The reservoir has insufficient pressure to get the fluid to the pump intake:

Conditions

A Multiphase fluid is specified in the Fluid Properties tab. An IPR and

Produced Fluid Flow Rate (surface) are specified in the Operating
Conditions tab. The pump intake (or tailjoint) is above the MidPerforations Measured Depth in the Equipment Configuration tab.
At the given Produced Fluid Flow Rate (surface) and IPR, the fluid level is
below the pump intake because the reservoir has insufficient pressure
to get the fluid to the pump intake.

Result

The PCP system is unable to pump fluid for the given Operating
Conditions due to inflow problems.
Check the following inputs to ensure that they are correct:
IPR(Operating

Remedial
Action

Conditions tab)
Produced Fluid Flow Rate (surface)(Operating Conditions tab)
If the above inputs are correct, consider lowering the pump intake by
increasing Pump Seating Measured Depth in the Equipment
Configuration tab so that there is sufficient inflow into the PCP.

3. PC-PUMP is unable to find the pressure on the IPR curve associated with the
fluid rate calculated from the pump speed:

Conditions

A Multiphase fluid is specified in the Fluid Properties tab. An IPR and Pump
Speed are specified in the Operating Conditions tab. The pump intake
(or tailjoint) is above the Mid-Perforations Measured Depth in the
Equipment Configuration tab.
The flow rate calculated by the software for the given Pump Speed is
not found on the IPR curve.

Result

The reservoir is unable to produce at the calculated for specified

pressure/flow rate.

Remedial
Action

Switch to the Operating Conditions tab and specify a Produced Fluid

Flow Rate (surface) instead of Pump Speed. Ensure that the Produced
Fluid Flow Rate (surface) is within the range of the IPR curve.

Alternative
Remedial
Action 1

Change the Pump Speed in the Operating Conditions tab until the error
no longer occurs. This may or may not work depending on the input
conditions. If this does not work, switch to the Produced Fluid Flow Rate
(surface) instead of Pump Speed.

You are here: Help/Troubleshooting > Errors > Error Message: "Negative pressure encountered. Please
review the input conditions"

Error Message: "Negative pressure encountered.

Please review the input conditions"
This help page summarizes the known causes of the error message "Negative
pressure encountered. Please review the input conditions" and identifies steps
to follow to avoid the error. If this page does not contain applicable steps to
avoid this error, please contact PCPUMP Technical Support for assistance. C-FER
will continually work to update this help page to include new reasons for PCPUMP encountering the error.
Always begin the troubleshooting of an error by ensuring that all inputs in the
Wellbore Geometry, Equipment Configuration,Fluid Properties and Operating
Conditionstabs are correct.
This error occurs in PCPUMP when calculated pressure losses result in a
negative pressure somewhere in the completion. The following list summarizes
the design scenarios which result in this error, and recommended changes to
the design to prevent this error from being generated:
1. There is a negative pressure in the annulus between the perforations and
the pump intake:

Conditions

The pump intake (or tailjoint) is below the Mid-Perforations Measured

Depth, and there is low clearance between the outside diameter of the
tubing, tail joint and/or pump and the casing drift diameter (check the
Equipment Configuration tab). There may also be a low Oil API Gravity
and/or high Total Fluid Viscosity in the Fluid Properties tab. There are
high flow losses in the casing/tubing or casing/tail joint annulus.

Result

Fluid is unable to reach the pump intake for the given Operating
Conditions due to friction losses.

Remedial
Action

Increase the clearance between the casing and tubing. To do so, select
a smaller diameter tubing, tail joint and/or pump in the Equipment
Configuration tab.

The operating conditions can also be changed to help overcome the

losses in the annulus. The user may do so by manipulating the following
parameters as applicable in the Operating Conditions tab:
Alternative
Remedial
Action 1

Produced Fluid Flow Rate (surface): Decrease;

Pump Speed: Decrease;

Motor Operating Frequency: Decrease;

Fluid Level: Decrease (i.e. fluid closer to surface);
Submergence (measured): Increase (i.e. fluid closer to surface);
or
Bottomhole Pressure: Increase.

Alternative
Remedial
Action 2

If for some reason the clearance in the casing/tubing annulus cannot be

increased (such as restrictions in the wellbore geometry), diluent
injection down the casing could be used to reduce the flow losses in the
annulus. C-FER recommends considering increasing the clearance as
much as possible and looking at the Operating Conditions before
considering this option.
For more information, see the Diluent Injection Fluid Properties and
Diluent Injection Tubing Selection help page.

You are here: Help/Troubleshooting > Errors > Error Message: "Unable to locate Gas Liquid Interface"

Error Message: "Unable to locate Gas Liquid

Interface"
This help page summarizes the known causes of the error message "Unable to
locate Gas Liquid Interface" and identifies steps to follow to avoid the error. If
this page does not contain applicable steps to avoid this error, please contact
PCPUMP Technical Support for assistance. C-FER will continually work to update
this help page to include new reasons for PC-PUMP encountering the error.
Always begin the troubleshooting of an error by ensuring that all inputs in the
Wellbore Geometry, Equipment Configuration,Fluid Properties and Operating
Conditionstabs are correct.
This error occurs in PCPUMP when the fluid level is too high (i.e. above
ground). The following list summarizes the design scenarios which result in
this error, and recommended changes to the design to prevent this error from
being generated:
1. High gas rate up casing:

Conditions

A Multiphase fluid is selected, possibly with a high Producing GLR or

Producing GOR in the Fluid Properties tab. There is a large quantity of
gas flowing up the annulus.

Result

At the given input conditions, liquid and gas are flowing up the casing.
While this can be achieved physically, PC-PUMP does not handle this
situation.

Remedial
Action

The pump pressure loading, pump torque, and rod loading can still be
analyzed in a case where fluid would be flowing up the annulus by
increasing the Casing Head Pressure in the Operating Conditions tab.
This will "push" the fluid level back below surface so fluid is not flowing
up the casing in PC-PUMP. Note that the total fluid rate in reality could be
higher than what is calculated in PC-PUMP using this workaround because
PC-PUMP does not consider the fluid flowing up the casing. Also, the fluid
level and submergence provided in the analysis results will not be valid
when increasing the Casing Head Pressure to remove this error.

You are here: Help/Troubleshooting > Warnings > Warning Message: "Temperature above critical
temperature/pressure below saturation pressure. Steam flashing may occur"

Warning Message: "Temperature above critical

temperature/pressure below saturation pressure.
Steam flashing may occur"
This help page summarizes the known causes of the warning message
"Temperature above critical temperature/pressure below saturation pressure.
Steam flashing may occur" and identifies steps to follow to avoid the warning.
If this page does not contain applicable steps to avoid this warning, please
contact PCPUMP Technical Support for assistance. C-FER will continually work to
update this help page to include new reasons for PCPUMP encountering the
warning.
This warning occurs in PCPUMP when the temperature exceeds the
saturation/critical temperature of water, and there is water flashing to steam
conditions specified in PCPUMP. PCPUMP is not currently capable of handling a
case with steam flow, so the results may not be valid. If water is flashing to
steam, it could affect the pressure gradient as well as enter the pump and
reduce the volumetric efficiency (similar to produced gas). The following list
summarizes the design scenarios which result in this warning, and
recommended changes to the design to prevent this warning from being
generated:
Conditions

High temperatures and/or low pressures are present in the wellbore.

Result

Water flashes to steam at the conditions specified in PCPUMP.

Remedial
Action

Check that all inputs are correct and representative of the

conditions (particularly temperatures and pressures in the
Conditions tab). If inputs are not representative of
conditions, re-enter them in the Operating Conditions
recalculate the case.

Alternative
Remedial
Action 1

downhole
Operating
downhole
tab and

Increase the wellhead pressure until it is high enough to prevent

steam flashing. The higher the bottomhole temperature is, the higher
the pressure will need to be to avoid steam flashing. Depending on
the configuration of the well, both the Tubing Head Pressure and
Casing Head Pressure may need to be increased. Note that despite
removing the warning message in PCPUMP, water may actually flash
to steam in the well at lower pressures. Steam entering the pump will
affect the pressure gradient as well as reduce the volumetric efficiency

compared to what is calculated in the program, so the results of the

calculation may not be valid.

Alternative
Remedial
Action 2

If the inputs are consistent with expected downhole conditions, check

if there are excessive flow losses (due to high viscosity or low
clearance) that may be causing a very low pressure in the wellbore.
Lower pressures will result in a lower critical temperature and could
be causing the warning.

You are here: Help/Troubleshooting > Warnings > Note: "Oil API gravity is outside the recommended range
of 15 to 150 API"

Note: "Oil API gravity is outside the

recommended range of 15 to 150 API"
This help page summarizes the known causes of the note "Oil API gravity is
outside the recommended range of 15 to 150API". If this page does not
contain applicable information as to why you have encountered this message,
please contact PCPUMP Technical Support for assistance. C-FER will continually
work to update this help page to include new reasons for encountering this
note.
This message is displayed in PCPUMP when oil API gravities outside of the
range of 15-150 API are entered into the program. Typically, users will have
entered a heavy oil (less than 15 API) when encountering this message.
Most correlations use API gravity and temperature to calculate a dead oil
viscosity even though the dead oil viscosity of heavy oils does not correlate
well with just API gravity and temperature. With heavy oil, C-FER recommends
the Use Advanced Viscosity option in the Fluid Properties tab. The Use Advanced
Viscosity option can significantly improve the results of the calculations with
heavy oil, since the program will not need to use a correlation to calculate
dead oil viscosity.
The dead oil viscosity correlation usually has the highest error with heavy oil
compared to other correlations. However, when using Advanced Viscosity with
heavy oil, the "Oil API gravity is outside the recommended range of 15 to 150
API" message will still be displayed as a reminder that other correlations may
also have reduced accuracy.

You are here: Help/Troubleshooting > Warnings > Warning Message: "High sand cuts (>10%) may cause
calculation errors"

Warning Message: "High sand cuts (>10%) may

cause calculation errors"
This help page summarizes the known causes of the warning message "High
sand cuts (>10%) may cause calculation errors". If this page does not contain
applicable information, please contact PCPUMP Technical Support for assistance.
C-FER will continually work to update this help page to include new
information.
This warning occurs in PCPUMP when a high sand cut (>10%) is entered. The
following table summarizes addition information about the calculation of
water-oil-sand mixture density PCPUMP:

Conditions

A single-phase fluid and a sand cut of >10% have been entered in the
Fluid Properties tab.

Result

The fluid density used in the PC-PUMP calculations may not be

representative of conditions in the well unless certain assumptions are
valid (see below).

The density of a water-oil-sand mixture in PC-PUMP is calculated with

the following assumptions:
1. The sand cut is based on the level of sand in a test tube after
being spun in a centrifuge.
2. The water cut is based on the difference in the level of the sand
and in the oil/water interface in the test tube.
3. The sand has a porosity of 40%.
4. The porosity of the sand is filled entirely with water. (This means
that even if the water cut is entered as 0%, the program will
assume that there is some water if the sand cut is greater than
0%.)
5. The velocity in the tubing is substantially greater than the sand
settling velocitythe assumption is that the sand travels through
the tubing at the same velocity as the liquid.

Additional
Information

As an example, consider a test tube containing 100 mL (0.0001 m) of

fluid and sand, after a centrifuge test. The bottom 50 mL of the test
tube is filled with sand, and the top 20 mL is filled with oil. This would
be entered in PC-PUMP as a water cut of 30% and a sand cut of 50%.
If the oil density is 850 kg/m, the water density is 1000 kg/m, and

the sand grain density is 2650 kg/m, then the fluid density can be
calculated as follows:
There is 20 mL (0.00002 m) of oil with a density of 850 kg/m (0.017
kg of oil). There is 30 mL of free water, plus 20 mL (40% of the 50 mL
of sand), of water in the pore spaces in the sand, for a total of 50 mL
(0.00005 m) of water at 1000 kg/m (0.05 kg of water). There is
actually only 30 mL (0.00003 m) of solid sand (due to its porosity),
at 2650 kg/m, for a total of 0.0795 kg. The total mass of the
contents of the test tube is then 0.017 + 0.05 + 0.0795 = 0.1465 kg.
The average density is calculated as 0.1465 kg / 0.0001 m = 1465
kg/m.
If the above assumptions are valid, then the density
calculation in PC-PUMP will be accurate, despite the warning
message.

You are here: Help/Troubleshooting > Warnings > Warning Message: "Negative pump axial load - removed
from calculations"

Warning Message: "Negative pump axial load removed from calculations"

This help page summarizes the known causes of the warning message
"Negative pump axial load - removed from calculations" and identifies steps to
follow to avoid the warning. If this page does not contain applicable steps to
avoid this warning, please contact PCPUMP Technical Support for assistance. CFER will continually work to update this help page to include new reasons for
PC-PUMP encountering the warning.
This warning occurs in PCPUMP when the net axial load on the rod string
results in an upward force. The following list summarizes the design scenarios
which result in this error, and recommended changes to the design to prevent
this error from being generated:
1. There is a high pump intake pressure and low differential pressure
resulting in a compressive force on the rod string:
Conditions

The pump intake pressure results in an upward force that causes a

negative axial load on part of the rod string.

Reason

PCPUMP calculations using rod string load are designed for when the rod
string is in tension. Compressive forces may result in bending and
buckling of the rod string so that tubing wear, rod fatigue, and spaceout calculations are affected.

Result

Calculations using rod load calculations may not be valid.

Remedial
Action

Increase the pump differential pressure or increase the pump intake

pressure. To do so, decrease the Fluid Level in the Operating Conditions
tab either manually or by increasing the fluid rate or pump speed when
an IPR is used.

You are here: Help/Troubleshooting > Warnings > Warning Message: "Tubing drift diameter is not large
enough to accommodate pump orbital diameter"

Warning Message: "Tubing drift diameter is not

large enough to accommodate pump orbital
diameter"
This warning is the result of the eccentric motion of the rotor head being
larger than the tubing diameter above the stator. If this page does not contain
applicable steps to avoid this warning, please contact PCPUMP Technical
Support for assistance. C-FER will continually work to update this help page to
include new reasons for PC-PUMP encountering the warning.
PCPUMP checks that the tubing diameter is large enough to allow for the
eccentric motion of the rotor (or orbital diameter) on the joint of tubing
directly above the pump. If the tubing diameter is not large enough for the
eccentric motion of the rotor, it may result in a hole in the tubing or a broken
rotor.
The warning can be fixed by adding a larger diameter joint of tubing above the
stator as follows:
1) Warning appears in Analysis Calculation Messages window:

2) Return to the Equipment Configuration tab, and open the Tubing Selection
window.

3) Add a tubing joint with a larger diameter to the existing tubing string.
Update the length of the existing tubing string by subtracting the length of the
new tubing joint.

4) Click OK and then Calculate. The Analysis Calculation Messages window should
no longer include the warning.

Note that pump vendors will often sell pumps with a larger diameter orbit tube
attached to provide sufficient clearance for the orbital diameter of the rotor.
PCPUMP does not currently track which pumps are supplied with these larger
diameter orbit tubes. It is important to check with the pump vendor to see if
an orbit tube is included with the pump. PCPUMP will allow the user to specify

that the pump is supplied with the proper diameter orbit tube and override the
warning.
In the Equipment Configuration window, in the Pump Selection window:
1. Check the box for Pump is supplied with the proper size orbit tubing.
2. Once this box is selected, the warning message will no longer appear in
the Analysis Calculation Messages window.

You are here: Help/Troubleshooting > Warnings > Warning Message: "Low clearance between rod guide and
tubing"

Warning Message: "Low clearance between rod

guide and tubing"
This help page summarizes the known causes of the warning message "Low
clearance between rod guide and tubing" and identifies steps to follow to avoid
the warning. If this page does not contain applicable steps to avoid this
warning, please contact PCPUMP Technical Support for assistance. C-FER will
continually work to update this help page to include new reasons for PC-PUMP
encountering the warning.
This warning occurs in PCPUMP when the clearance between the rod guide and
tubing is less than the minimum clearance in the tubing specified in the
Preferences window. The following list summarizes the design scenarios which
result in this error, and recommended changes to the design to prevent this
error from being generated:
1. Clearance between rod guide and tubing less than the specified minimum:

The clearance between the rod guide flow diameter and the tubing
drift diameter is low.
Conditions

The value prescribed in the Default Tolerances tab for Minimum

equipment clearance in tubing is higher than the clearance between
the rod guide flow diameter and the tubing drift diameter.

Result

There is insufficient clearance between the rod guide and tubing in the
wellbore.

Remedial
Action

This warning can usually be ignored since many rod guides are
designed to fit snugly into tubing. To "turn off" the warning, go to Edit > Preferences -> Default Tolerances and decrease the Minimum
equipment tolerance in tubing until the warning disappears. Note that
this feature is intended to check that all equipment that fits inside the
tubing will provide sufficient clearance for fluid flow. If it is turned off,
extra attention will be needed to ensure that proper clearance is
provided in the tubing.

Additional
Information

The Preferences -> Default Tolerances window appears as below:

You are here: Help/Troubleshooting > Warnings > Warning Message: "Selected equipment may no longer be
available from the manufacturer/vendor"

Warning Message: "Selected equipment may no

longer be available from the
manufacturer/vendor"
This help page summarizes the cause of the warning message "Selected
equipment may no longer be available from the manufacturer/vendor". If this
page does not contain applicable information, please contact PCPUMP Technical
Support for assistance. C-FER will continually work to update this help page to
include new information.
This warning occurs in PCPUMP when obsolete equipment is used in a PCP
system
design.
Manufacturers/vendors
periodically
update
the
PCPUMP equipment database, which may involve identifying previously
available equipment as obsolete. Obsolete equipment is kept in the database
to allow users to perform calculations if needed, but users are encouraged to
contact their manufacturers/vendors for more information when this warning
occurs since the equipment may have been replaced with newer models.
To assist in designing a PCP system without obsolete equipment, the user can
choose to not display obsolete equipment in PCPUMP. To do this, navigate to
Default Switches in the Preferences window and deselect Display obsolete surface
equipment in dropdown menus and/or Display obsolete downhole equipment in dropdown
menus. Deselecting these options will remove obsolete equipment from all dropdown menus.

Checking the

and/or Display
obsolete downhole equipment in dropdown menus options will display obsolete
equipment in the drop-down menus, marked as "<Obsolete Equipment>":
Display obsolete surface equipment in dropdown menus

You are here: Help/Troubleshooting > Warnings > Warning Message: "Convergence error on pump speed"

Warning Message: "Convergence error on pump

speed"
This help page summarizes the known causes of the warning message
"Convergence error on pump speed" and identifies steps to follow to avoid the
warning. If this page does not contain applicable steps to avoid this warning,
please contact PCPUMP Technical Support for assistance. C-FER will continually
work to update this help page to include new reasons for PC-PUMP encountering
the warning.
When pump speed is specified as an input, PCPUMP does an iterative
calculation. This warning occurs in PCPUMP when this iterative calculation is
unable to converge on the specified pump speed.
The following list summarizes the scenarios which result in this warning, and
recommended changes to the design to prevent this error from being
generated:
Conditions

There is a pump speed defined in the Operating Conditions tab.

Reason

PCPUMP calculations using pump speed are iterative, and in some cases
are not able to converge on a fluid rate that results in the specified
pump speed.

Result

Calculations using an input for pump speed may not be valid.

Remedial
Action

Specify a Fluid Flow Rate in the Operating Conditions tab.

You are here: Help/Troubleshooting > Messages > Message: "Rod/tubing wear calculated in boronized
tubing joints using adjusted wear coefficients"

Message: "Rod/tubing wear calculated in

boronized tubing joints using adjusted wear
coefficients"
This help page provides more information about the message "Rod/tubing wear
calculated in boronized tubing joints using adjusted wear coefficients". If this
page does not contain applicable information, please contact PCPUMP Technical
Support for assistance. C-FER will continually work to update this help page to
include new information.
This message is shown in PCPUMP when boronized tubing is used in a PCP
system design. Boronized tubing is tubing that is hardened through a diffusion
alloying process to mitigate rod wear issues that are common in PCP
applications.
In PCPUMP, rod/tubing contact loading is calculated based on the wellbore
geometry and the calculated axial load at each point in the rod string. The
calculated axial load at each contact point is then used to calculate the
rod/tubing wear as follows:
W = 1.9548x10-5 X 10(0.075 Y

S)

Where:
W = Tubing Wear Rate (mm/MRevs)
S = Sand Cut (%)
F = Distributed Contact Load (N/m)
X,Y = Wear Coefficients
This formula was developed through a CFER study on rod/tubing wear50. The
empirical wear data suggested that wear rates were linearly related to
rod/tubing contact loads and exponentially related to sand cut. Default
coefficients (X and Y) for metal couplings and urethane couplings/rod guides
were determined to be as follows:
Rod Contact Material

Tubing Contact Material

X Coefficient

Y Coefficient

Steel

Steel

1.0

1.0

Urethane

Steel

0.75

0.9

Previously, PCPUMP did not contain coefficients to estimate rod/tubing wear in

boronized tubing. Using the results of an abrasive wear test (ASTM G65) on
50W steel (50 ksi yield strength, 95 ksi tensile strength) and boronized steel
tubing, the following adjusted wear coefficients were developed to estimate
rod/tubing wear in boronized tubing:
Rod Contact Material

Tubing Contact Material

X Coefficient

Y Coefficient

Steel

Boronized

0.070

1.0

Urethane

Boronized

0.053

0.9

For more details about the adjusted wear coefficients for use with boronized
tubing, please contact PCPUMP Technical Support.

You are here: Help/Troubleshooting > Messages > Message: "Rod/tubing wear calculated in HDPE lined
tubing joints using default wear coefficients"

Message: "Rod/tubing wear calculated in

HDPE lined tubing joints using default wear
coefficients"
This help page provides more information about the message "Rod/tubing wear
calculated in HDPE lined tubing joints using default wear coefficients". If this
page does not contain applicable information, please contact PCPUMP Technical
Support for assistance. C-FER will continually work to update this help page to
include new information.
This message is shown in PCPUMP when HDPE lined tubing is used in a PCP
system design. HDPE tubing is tubing with a thermoplastic liner that is
intended to mitigate rod wear issues that are common in PCP applications.
In PCPUMP, rod/tubing contact loading is calculated based on the wellbore
geometry and the calculated axial load at each point in the rod string. The
calculated axial load at each contact point is then used to calculate the
rod/tubing wear as follows:
W = 1.9548x10-5 X 10(0.075 Y

S)

Where:
W = Tubing Wear Rate (mm/MRevs)
S = Sand Cut (%)
F = Distributed Contact Load (N/m)
X,Y = Wear Coefficients
This formula was developed through a CFER study on rod/tubing wear50. The
empirical wear data suggested that wear rates were linearly related to
rod/tubing contact loads and exponentially related to sand cut. Default
coefficients (X and Y) for metal couplings and urethane couplings/rod guides
were determined to be as follows:
Rod Contact Material

Tubing Contact Material

X Coefficient

Y Coefficient

Steel

Steel

1.0

1.0

Urethane

Steel

0.75

0.9

PCPUMP does not currently contain coefficients to estimate rod/tubing wear

specifically in HDPE lined tubing. When calculating wear rates in HDPE lined
tubing, PCPUMP will use the defaults in the table above.
It is highly recommended that rod/tubing wear calculation results for
HDPE lined tubing be validated using observations and field data. For more
details about calculating adjusted wear coefficients for use with HDPE lined
tubing, please contact PCPUMP Technical Support.

You are here: Sample Sessions > Introduction

SAMPLE SESSIONS
Introduction
The sample sessions in this chapter support the information provided in the
Help File by providing eight sample sessions that demonstrate the use of some
of PCPUMP's capabilities and features.
The sample sessions increase successively in terms of the number of features
utilized as well as their level of complexity. Later sample sessions assume that
you are familiar with the concepts introduced in the previous sessions.
Consequently, inexperienced users should complete these sessions in order.
The following list provides a summary of the features which are demonstrated
in the respective sessions:
Session 1: Basic Pump Change
Setting Preferences
Selecting Downhole Equipment
Specifying Single Phase Fluid Properties
Specifying Standard Operating Conditions
Conducting Standard Calculations
Session 2: Horizontal Well Design
Specifying a Wellbore Geometry
Selecting Surface Equipment
Using the Advanced Density Option
Using Rod Guide Optimization Mode
Conducting Rod String Space-Out Calculations
Conducting Rod/Tubing Wear Analyses
Session 3: Heavy Oil Well Conversion
Specifying Multiple Equipment Cases
Using the Advanced Viscosity Option
Using Equipment Comparison Mode
Using Pump Comparison Mode
Session 4: Well Production Optimization
Using an IPR (Inflow Performance Relationship)

Specifying Pump Test Information

Using Batch Comparison Mode
Session 5: Conventional Oil Application
Specifying Multiphase Fluid Properties
Selecting a Tail Joint
Session 6: Backspin and Fatigue Analyses
Conducting a Backspin Analysis
Conducting a Rod String Fatigue Analysis
Session 7: Basic Downhole Drive
Using the Case Manager
Specifying Downhole Drive Equipment
Session 8: Advanced Downhole Drive
Using a Shroud
Calculating Temperature Effects of a Downhole Motor
Session 9: Heat Transfer
Heat Transfer Module
The above sample sessions are fictitious examples created to demonstrate the
use of PCPUMP for downhole progressing cavity pumping (PCP) systems. All of
the equipment used in the sample sessions was selected for illustrative use
only.
Note: The samples in this Help File are based on PCPUMP v3.3.9. If you are
using a later version of the program, or an updated database, some of the
results you get may not be the same as those in this Help File. Also, some of
the equipment selected in this Help File may no longer be available in the
database. If this is the case, select the closest match available.

Related Topics
Printing Reports
Using Tables and
Charts
Acknowledgments

Copyright
Cover Page

You are here: Sample Sessions > Session 1: Basic Pump Change

Session 1: Basic Pump Change

Note: The samples in this Help File are based on PCPUMP v3.4. If you are
using a later version of the program, or an updated database, some of the
results you get may not be the same. Also, some of the equipment selected in
this Help File may no longer be available in the database. If this is the case,
select the closest match available.
As an introduction to PCPUMP, this session describes the process which might
be followed to assess the impacts of implementing a pump change.
It
illustrates how to start the program, set user preferences, save files, select
surface drive equipment, enter single-phase fluid properties and standard
operating conditions, perform standard calculations and review summary
output parameters and output messages.

Scenario:
It is anticipated that by pumping the fluid level of a well down to 700 m, the
well's production rate can be increased to 150 m3/D from its current rate of
100 m3/D. However, the currently installed Weatherford (BMW) 28-1200
pump is already operating at a speed in excess of 350 RPM. A Weatherford
(BMW) 56-1000 pump which has a larger displacement but lower pressure
rating is also available.

Objective:
Determine if either of these pumps is suitable for achieving the increased
production rate. In addition, check if there will be a problem with rod string
loading under the proposed operating conditions.

Data:
Wellbore Geometry
Well Type: Assume Vertical (no wellbore geometry provided)
System Configuration:
Pump Seating Depth: 820 mKB (2700 ft)
Mid-Perforations: 800 mKB (2650 ft)
Casing: 177.8 mm x 34.23 kg/m

Tubing: 73.0 mm x 9.67 kg/m

Rod String: 22.2 mm Grade D standard rods with slimhole couplings (7.62
m length)
Existing PC Pump: Weatherford (BMW) 28-1200
- displacement = 0.280 m3/D/RPM (1.761 bbls/D/RPM)
- pressure rating = 12415 kPa (1800 psi)
- friction torque = 100 Nm (80 ftlbs)
- volumetric efficiency = 90%
Alternative PC Pump: Weatherford (BMW) 56-1000
- displacement = 0.560 m3/D/RPM (3.522 bbls/D/RPM)
- pressure rating = 9656 kPa (1400 psi)
- friction torque = 100 Nm (80 ftlbs)
- volumetric efficiency = 90%
Surface Equipment: Not being considered
Fluid Properties:
Fluid Composition
Water Cut: 70%
Sand Cut: 0%
Gas Specific Gravity: 0.7
Fluid Density (tubing and casing): 1000 kg/m3
Fluid Viscosity
Fluid Viscosity: 5 cp
Operating Conditions:
Fluid Rate: existing = 100 m3/D; proposed = 150 m3/D
Fluid Level: existing = 500 mKB; proposed = 700 mKB
Tubing Head Pressure: 150 kPa
Casing Head Pressure: 100 kPa
Bottomhole Temperature: 20 C
Temperature Gradient: 1 C /100 m

Procedure:
In this session, you will evaluate:

the current operating conditions for the existing pump;

the proposed operating conditions for the existing pump; and
the proposed operating conditions for the alternative pump.
The following issues need to be examined:
pump operating speed;
pump pressure loading; and
rod string loading.
To start PCPUMP, double-click on its program icon. After the initialization
routines are completed, the splash screen will appear. Then the main program
window will open to the Equipment Configuration tab in surface drive mode.
To customize some of PCPUMP's parameters, bring up the Preferences window
by clicking the Edit menu option and selecting "Preferences". Tabs along the
top allow you to switch between screens corresponding to units, default values,
default switches, default tolerances, correlations, paths and regional. Each tab
is explained in detail in the Help File included in the software.
In order to follow along with these sample sessions, make sure that all of the
units are set to Metric (SI) with the exception of power which should be set to
Oilfield. Simply move to the Units tab, then click the Set all to Metric units button
to change all units to Metric and finally toggle the power category from kW to
hp. When configured properly, the screen should appear as shown below.

Preferences - Units Input Window

Clicking the OK button returns you back to the Equipment Configuration

window and activates the changes.
When performing an analysis, it is recommended that tasks be carried out in
the following order:
specify wellbore geometry;
input pump seating and mid-perforation depths;
select a progressing cavity pump;
select casing, tubing, injection tubing, and tail joints or a shroud;
select rod string if the analysis is for a surface drive system;

select surface or downhole drive equipment;

specify fluid properties; and
specify operating conditions and IPR data.
The well in this first sample session is vertical so you do not need to specify a
wellbore geometry. Next, select the Equipment Configuration tab and input a
Pump Seating Measured Depth of 820 mKB and a Mid-Perforations Measured
Depth of 800 mKB in the two edit boxes to the left of the wellbore image.
Note that the pump seating depth corresponds to the location of the bottom of
the pump.
The Equipment Configuration tab allows you to select equipment from various
selection lists generated from PCPUMP's extensive equipment database. All of
the downhole equipment for surface drive cases (e.g. pump, casing, tubing and
rod string) must be properly selected before you can complete any
assessments. Note that selection of drive equipment is optional and will be
omitted in this first sample session.
To select a PC pump, click the Pump update button
in the Equipment
Configuration window. This will bring up the Pump Selection window which
allows you to select a pump, view its specifications and, if desired, assign
corresponding pump tests. The first step in selecting a pump is to choose a
pump vendor using the Company drop-down list in the upper left-hand corner
of the window. Once a vendor is selected, the table below will display all of
that vendor's pump models. (Note: some vendors may be listed twice to
accommodate both their new and old pump model designations.) To select a
pump model, click on the name in the table and the right-hand Details tab will
be updated with its corresponding specifications. The window includes a
performance Chart tab that displays either the nominal fluid rate or the power
versus pump speed at low and high speed ranges. Practice selecting pumps
and looking at their specifications.
For this sample session, select the Weatherford BMW (28-1200) model. Two
other important pump specifications are pump friction and volumetric
efficiency. In PCPUMP, these parameters can either be specified as static
values or calculated dynamically based on pump test data and operating
conditions. For this first sample session, use a static pump friction of 100 Nm
and a static volumetric efficiency of 90%. Either enter or change these values
within the respective edit boxes located in the lower portion of the Details tab
on the right-side of the window. Note that each time a pump is selected, these
parameters will be assigned values based on the defaults set in the
Preferences window. Once you have selected the pump and changed the static
parameters, your screen should appear as below.

When you have finished, close the Pump Selection window by clicking the OK
button and return to the Equipment Configuration window.
Within the
Equipment Configuration window, details of the selected pump will be displayed
in the pump summary list box on the right of the central system image.
To select a casing string, click the Tubular update button
in the Equipment
Configuration window. Components are selected from a drop-down list. Once
the component has been selected, the length of the string is automatically
entered using either the pump seating depth or the mid-perforations,
whichever is deeper. If you wish to enter strings of different sizes or extend
the casing below the pump seating depth, change the value in the Length
column. Segments can be deleted by right-clicking and selecting "Delete
Row(s)". Casing segments can be inserted by right-clicking and selecting
"Insert Row".
Note:
Casing segments will be added sequentially from the surface
downward, tubing segments from the top of the pump upward and tail joints
from the bottom of the pump downward.
For this sample session, specify 850 m of 177.8 mm x 34.23 kg/m casing.
When configuring casing, the string should always extend below the lowest of
the mid-perforations, pump intake or tail joint intake depths. When configured
as noted, the Casing Selection window should appear as shown below.

Click on the Tubing tab and repeat the above steps for the tubing string and
select 820 m of 73.0 mm x 9.67 kg/m tubing. Note that tubing strings do not
need to extend exactly to surface as PCPUMP automatically extends or ignores
the string as required. When configured as noted, the tubing windows should
appear as shown below.

To confirm your tubing selection and return to the Equipment Configuration

window, click the OK button. Any selections you have made will be displayed in
the tubular summary list box situated to the left of the system design image.
Next is the selection of the rod string components. Rod strings are specified
through a process where different string components are selected and then
added in a segmented manner from the pump rotor upwards toward surface.
To select a rod string, click the Rod String update button
in the Equipment
Configuration window.

Rod strings are constructed by specifying a rod element type through a series
of drop-down lists and then adding one or more of these elements to the rod
string. To configure a rod element, choose a rod type, size and grade,
coupling/centralizer and length. If you wish to add rod guides, you must also
select a particular type as well as the number of guides per sucker rod. Once
you have finalized a configuration, input either a number or length of rods,
then click the Add to Top or Insert buttons to append your selection onto the rod
string. As an option, the Fill to Surface button can be used to extend the string
to surface using the selected rod elements. Note that although polish rod
components are available, it is not mandatory to end the top of the string with
one. The current rod string configuration will be displayed in the table with
segments listed from top to bottom of the well. Practice adding and deleting
different types of rod segments.
For this session, consider a rod string comprised entirely of 22.2 mm Grade D
standard rods with 22.2 mm API slimhole couplings (7.62 m length). Before
you begin, make sure that you remove any existing rod segments by rightclicking anywhere in the table and selecting "Clear All Rows". Then select the
desired rod elements and click the Fill to Surface button. This should result in
the addition of 108 rod segments and produce a screen which appears similar
to that shown below.

Once you have finished specifying the rod string, click the OK button to confirm
your inputs and return to the Equipment Configuration window. Within this
window, the rod string summary table displays a summary of the currently
specified configuration. Note that identical rods are grouped together for more
convenient display.
After selecting this final equipment component, the
Equipment Configuration window should appear as below.

The next steps based on the task order defined previously would be the
selection of surface drive equipment and the configuration of equipment
cases. However, in this first example you will not consider surface equipment
and do not need to specify any equipment cases.
Now you must enter fluid properties by selecting the Fluid Properties tab in the
main window.
Fluid properties, can be toggled between Single-Phase and
Multiphase flow analysis modes. In this first sample session, you will use the
more basic single-phase fluid flow inputs. Values you must enter for the
sample session include: casing and tubing fluid densities of 1000 kg/m3, a
water cut of 70%, a gas specific gravity of 0.70, and a fluid viscosity of 5 cp

under the General Properties tab. When completed, the General Properties tab
should appear as below.

Next, enter the operating conditions by selecting the Operating Conditions tab
in the main window. Radio buttons on the side of the input area can be
switched between several states to designate different input and calculated
parameters. Select Produced Fluid Rate (surface) and Fluid Level as the input values.
You can then enter the existing fluid rate of 100 m3/D into the top edit box.
The remaining boxes in the operating information area are grayed out to
indicate that they are calculated parameters. Once a calculation has been
performed, they will be updated with the appropriate values. The next box
below corresponds to the fluid level and it can be toggled between joints,
vertical distance (Vertical m or Vertical ft) or measured distance (mKB or ftKB)
from surface down to the fluid level. Because this is a vertical well, the
existing fluid level of 500 m can be entered as either a vertical or measured
distance. Click Specify Temperature and enter Bottomhole Temperature of 20C
and a Temperature Gradient of 1C/100 m to describe the temperature profile
of the well. Finally, enter a Tubing Head Pressure of 150 kPa and a Casing
Head Pressure of 100 kPa into the respective edit boxes. The Operating
Conditions window should appear as shown below.

With the equipment configuration, fluid properties and operating conditions

inputs specified, you are now ready to perform an assessment. First, check
the cases you want to assess from the Case Manager. Click the Calculate button
to start the computation process. Following a brief calculation period, the
Analysis Results tab will appear as shown below for each case that completed
the analysis successfully.

When you perform a calculation, an entire array of results are generated. Each
section of results is displayed in a separate tab. The first tab contains a
summary of the results. On the left-side of the summary tab, fluid properties
and operating conditions are summarized. Parameters commonly used to
measure system performance are designated as summary output conditions
and are displayed along the right-hand side of the window. Output messages
generated during the analysis are shown in the bottom portion of the screen.
Several additional output windows which contain detailed information on
specific topics can be accessed using the tabs at the top of the window. Note
that access to some of the output windows is limited to specific types of

analysis (e.g. multiphase, comparison mode, downhole or surface drive).

A review of the first set of results reveals that the existing design is
satisfactory. The pump is operating at a speed of 397 RPM, the pump pressure
loading is 40% and the maximum rod stress is 99.5% of yield.
Now, change the inputs to represent the proposed fluid rate of 150 m3/D and
fluid level of 700 m. This can be done by moving back to the Operating
Conditions tab and making the necessary modifications to the inputs, and
clicking the Calculate button. Under these proposed conditions, the pump would
be operating at 595 RPM, the pump pressure loading would be 57% and the
maximum rod stress would be 52% of yield. Although the pump loading and
rod stresses remain acceptable, the pump speed of 595 RPM would be
considered unacceptable in most applications. Note that an output message
acknowledges the occurrence of a high pump speed.
Finally, perform an evaluation with the alternative pump at the proposed
operating conditions.
This can be done in the Case Manager area by
highlighting the pump, right-clicking and selecting "Copy Case" thus making a
copy of the first case. You can then switch the pump model to the 56-1000
pump model by selecting the Pump update button in the Equipment
Configuration window. When finished, click the Calculate button. Following the
calculation, the Analysis Results window should appear as shown below.

The output for this second case indicates that the required speed would
decrease to 298 RPM with the larger displacement pump alternative. However,
because of its lower pressure rating, the pump pressure loading would increase
to 73%. The maximum rod stress would also be higher at 77 % of yield.
Overall, the alternative pump represents a better choice for the proposed
operating conditions because of the respective speed requirements. Although
several other loading parameters would also increase in value, the analysis
results show they will remain within acceptable design guidelines.
When using PCPUMP to perform pumping system assessments, it is
recommended that you periodically save your work. File saving is not only
useful for future reference, but it will also be helpful should your design be
accidentally modified or your computer system crash. PCPUMP saves and
restores your assessments in the form of data files. A single saved file will
contain all of your input information including wellbore profiles, equipment
specifications, fluid properties and operating conditions. To save a data file,
simply click the File menu option, select "Save" or "Save As" and enter a
filename. If the file has previously been saved, PCPUMP will use that file name

when this command is executed.

To become familiar with the programs basic operation, try changing the input
options and examine their corresponding effect on the summary output
conditions and output messages. Different equipment and operating scenarios
can be evaluated and compared to come up with an optimal system
configuration.
This first sample session was intended to provide an introduction to PCPUMP
and to demonstrate the use of the software in its most basic mode. In the
subsequent sample sessions, you will be introduced to PCPUMPs advanced
features, different calculation modes and the various output windows. You are
reminded that these sessions are not intended to serve as a comprehensive
technical reference. Detailed documentation on the many features of PCPUMP
is contained in the main sections of the Help File.

You are here: Sample Sessions > Session 2: Horizontal Well Design

Session 2: Horizontal Well Design

Note: The samples in this Help File are based on PCPUMP v3.4. If you are
using a later version of the program, or an updated database, some of the
results you get may not be the same. Also, some of the equipment selected in
this Help File may no longer be available in the database. If this is the case,
select the closest match available.
This sample session will show you how to use PCPUMP to design a new
horizontal well. The session reinforces the concepts presented in the first
session and introduces the Wellbore Geometry window, well design mode,
surface drive equipment evaluation, rod guide optimization mode, advanced
viscosity option and several of the output windows.

Scenario:
Two new horizontal wells have been proposed to increase production in a field
currently being produced by a single horizontal well. These wells are expected
to produce at rates of between 100 and 125 m3/D with a stabilized fluid level
of 400 Vm. To minimize surface land use and centralize surface facilities,
these wells will be drilled from the surface pad of the existing horizontal well.
To reach the subsurface coordinates target, the well profiles must have built-in
plan view curvature as illustrated in the diagram below.

Objective:
Design a well profile and select a suitable surface drive PC pumping system
configuration. Unless it creates design problems, use the same casing, tubing
and pump as the existing horizontal well. With respect to the rod string, any
configuration except continuous rod (because of the remote well location) is an
option. Key design considerations include an appropriate wellbore profile, rod
string loading, rod/tubing contact loading and wear, and sizing of the surface
equipment.

Data:
Wellbore Geometry
Well Type: Horizontal
- target vertical depth = 450 m (5 m)

- lateral offset = 100 m (Well #2 West, Well #3 East)

- departure before target depth = 300 m (North)
- horizontal section = 500 m
System Configuration:
Casing: 177.8 mm x 34.23 kg/m (same as existing well)
Tubing: 88.9 mm x 13.8 kg/m (same as existing well)
Rod String: To be determined
PC Pump: R&M Energy Systems Moyno Brand (8-N-44) (same as
existing well)
- seated at 85
- displacement = 0.446 m3/D/RPM
- pressure rating = 8070 kPa
- pump friction = 100 Nm
- volumetric efficiency = 90%
Surface Equipment: To be determined
Fluid Properties:
Fluid Composition
Water Cut: 10% (based on existing well)
Sand Cut: 0%
Gas Specific Gravity: 0.7
Oil API Gravity: 22API
Water Specific Gravity: 1.05
Fluid Viscosity
Fluid Viscosity: 100 cp
Operating Conditions:
Fluid Rate: target = 100 to 125 m3/D
Fluid Level: target = 400 Vm
Tubing Head Pressure: 500 kPa (based on existing well)
Casing Head Pressure: 50 kPa (based on existing well)
Bottomhole Temperature: 22C
Temperature Gradient: 0.5 C /100 m

Procedure:
In this session, you will determine a:
horizontal well profile design;
downhole equipment (pump, tubulars, rods) configuration; and
surface drive equipment configuration.
The following issues need to be addressed:
well geometry to meet target specifications;
pump operating conditions;
rod string loading and space-out;
rod/tubing contact loads;
rod/tubing wear; and
surface drive equipment operation.
The first step of this assessment is the creation of a suitable directional well
profile. After starting PCPUMP, click the Wellbore Geometry tab to move into
the well geometry portion of the program. Within this module, you can input,
process and display survey data and charts for either existing or proposed
directional well geometries. Because you are designing a new well and there
is no directional survey available, the well design mode must be used to create
a directional proposal. Bring up the Well Design window by clicking the Well
Design button.
Within Well Design window, you can create a directional wellbore survey by
entering a series of lengths, build rates and plan curvatures into the left-side
of the table. Note that positive build rates correspond to a wellbore that is
increasing angle while positive plan curvature corresponds to a wellbore that is
moving left to right in plan view. When you click the OK button, each
segment's measured depth, hole angle, azimuth, dogleg severity, vertical
depth, horizontal distance, latitude and departure will be computed and
displayed. You can also examine the profiles graphically by selecting the Chart
tab at the top of the window. For practice, try constructing some different well
profiles. Right-click to insert rows, delete a row or delete all rows.
For this particular example, you must construct a well profile that will reach
horizontal (i.e. 90) at a total vertical depth (TVD) of 450 m and an East-West
departure of 100 m. In addition, the target TVD must be established by 300 m
North of surface and hold at this depth for 500 m. Although this can be
achieved using numerous different well shapes, for consistency create a well

profile with the following segments:

Segment Length Build Rate

Plan Curvature

64.6 m

0 /30m

0 /30m

95 m

3 /30m

0 /30m

210 m

5 /30m

6 /30m

210 m

5 /30m

-6 /30m

105 m

3 /30m

0 /30m

500 m

0 /30m

0 /30m

Once you have entered the data into the spreadsheet, the updated screen will
appear as shown below.

The proposed wellbore will have a final measured depth of 1184.6 mKB, hole
angle of 90, vertical depth of 450 m and departure of 99.9 m. Select the
Chart tab to view the profile graphically. As you will use this profile for the
analysis, click the OK button to exit Well Design window.
Upon exiting the Well Design window, a directional proposal spaced at 10 m
will be generated based on the specified inputs. The proposal survey data will
be displayed within the large table in the Table tab of the Wellbore Geometry
window. If necessary, use the horizontal and vertical scroll bars to move about
the table in order to access the full range of data. Note that at hole angles of
85 and 90, the corresponding measured depths are approximately 635 mKB
and 685 mKB, respectively.
To view the directional well data in graphical form, select the Charts tab to
bring up the window shown below.

Use the Chart drop-down list to switch between the different chart types that
are available.
In addition to the detailed information displayed in the survey table, PCPUMP
also calculates several other parameters related to wellbore geometry. This
summary information is displayed in the Summary tab. The Summary tab for
the proposed well should appear as shown below.

Now that you have generated an appropriate wellbore profile, continue with
the assessment by moving to the Equipment Configuration tab.
As in the previous sample session, begin by specifying the pump seating and
mid-perforation locations. Recall from the Wellbore Geometry window that the
desired pump seating angle of 85 corresponds to a measured depth of
635 mKB. For a horizontal well, you may consider the mid-perforation
location to be the beginning of the horizontal section, which in this well occurs
at a measured depth of 685 mKB. Enter these two locations in the appropriate
input fields.
Next, specify downhole equipment in a similar manner as in the first sample
session. Begin by selecting a R&M Energy Systems Moyno Brand (8-N-44)
pump, and assign it a Pump Friction value of 100 Nm and a Static Volumetric
Efficiency of 90%. Then select 700 m of 177.8 mm x 34.2 kg/m casing and
635 m of 88.9 mm x 13.80 kg/m tubing. Because the rod configuration was
not defined, start with a rod string made up of API 22.2 mm Grade D standard
rods with 22.2 mm API slimhole couplings (7.62 m length).
Next, define the surface drive equipment by clicking the Surface Drive Equipment
update button
in the Equipment Configuration window. Tabs at the top of
the screen are used to move among entry dialogs for the four major surface
drive equipment components. It is recommended that you configure surface
equipment by starting at the drivehead and proceeding toward the prime
mover. Although you must specify both a drivehead and a prime mover, belts
and hydraulics are optional components.
For this session, assume a surface drive equipment configuration comprised of
a drivehead, belts and an electric motor with an adjustable speed control
system. From within the Drivehead tab of the Surface Drive Equipment
Selection window, start by selecting National-Oilwell as a vendor and then
choosing the AV1-4-7/8 model drivehead. After you have selected this model,
the screen will be updated with several corresponding specifications which
include its maximum power rating of 20 hp and maximum speed of 500 RPM.

Next, switch to the Belts tab and check the Drive equipment includes belts box. This
will give you access to the edit boxes into which you enter a Reduction Ratio of
3:1 and a Power Transmission Efficiency of 95%.
Now advance to the Prime Mover tab, which is the final drive component which
is to be selected. PCPUMP currently only supports electric motor based
assessments. For this particular application, begin by specifying a Motor Power
Rating of 20 hp, 6 Motor Poles, a nominal Motor Efficiency of 92% and a
nominal Power Factor of 0.8.
The two other input parameters, supply
frequency and voltage, should automatically be assigned values of 60 Hz and
460 V based on the Preferences defaults. Note that as you enter the various
specifications, values for the motor speed and full load current will be
calculated and displayed.
The last step in specifying surface drive equipment is to set an option for
matching the pump speed to the prime mover speed. When performing
analyses in PCPUMP, the pump speed is input either directly or through the
entry of a fluid rate. However, in most cases the selected surface drive
equipment configuration will not generate this speed. As a result, the drive
equipment specifications must be adjusted to match the pump speed. At the
bottom of the Prime Mover tab are two radio buttons that allow you to choose
the way in which the pump speed is matched to the surface equipment.
Options include adjusting the prime mover speed (i.e. by modifying the
operating frequency), belt reduction ratio or hydraulic pump displacement. To
simulate the use of an adjustable speed control system, select the Match pump
speed by adjusting primer mover speed option.
The Prime Mover tab should appear as shown below.

Once you have finalized the surface drive equipment selection, click the OK
button to return back to the Equipment Configuration window. A summary of
the selected surface drive equipment will be displayed in a summary list box.
The Equipment Configuration window should now appear as displayed below.

With the specification of the wellbore profile and equipment now complete, you
can move on to the Fluid Properties tab. For this session, you will once again
use single-phase fluid properties and standard operating conditions. Although
fluid density was not specified directly, the input conditions provided can be
used to determine it using the Calculate Fluid Density option. This option allows
you to calculate total fluid densities based on oil, water and sand gravities as

well as the water fraction and sand cut.

In the Calculate Fluid Density option, you must first enter the Oil API Gravity which
is 22API. Next, because you need to account for produced water effects,
enter the Water Cut of 10% and the Water Specific Gravity of 1.05. Because
this well does not produce any sand, specify a Sand Cut of 0% and ignore the
sand specific gravity input. The tubing and casing density factor inputs are
used to adjust the fluid densities to account for produced gas effects. For this
example, leave them at their default values of 1.00 (i.e. no adjustment). The
tubing and casing density boxes should automatically fill in with a value of
920 kg/m3. Finish specifying the fluid properties by entering a Gas Specific
Gravity of 0.70, and a Total Fluid Viscosity of 100 cp (the latter under the Fluid
Viscosity tab).
When completed, the Fluid Composition tab of the Fluid
Properties window should appear as below.

Next, select the Operating Conditions tab. Select the Produced Fluid Flow Rate and
Fluid Level radio buttons so that they are the inputs and the remaining
parameters in the Operating Information area are calculated values. It is
prudent to start the analysis with the most severe loading scenario expected
which, in this case, corresponds to the maximum Fluid Flow Rate of 125 m3/D.
In the Fluid Level edit box, enter the target level of 400 Vertical m (i.e.
vertical metres). If you select other depth measures from the drop-down list,
the fluid level will be displayed as 48.2 jts (equivalent 9.6 m length tubing
joints) and 462.4 mKB (measured depth). Enter a Bottomhole Temperature of
22C and a Temperature Gradient of 0.5C/100 m to define the well's
temperature profile. Lastly, enter a Tubing Head Pressure of 500 kPa and a
Casing Head Pressure of 50 kPa into the remaining edit boxes. The Operating
Conditions window should appear as shown below.

With the system configuration and analysis inputs specified, click the Calculate
button to start the analysis. The Analysis Results window should appear as
shown below.

Review the results, examining the particular issues being addressed in this
session.
The first consideration is pump operation.
Results from the
assessment indicate that the pump would operate at a speed of 311.41 RPM
and be loaded at 53.86% of its pressure rating. Both of these conditions are
satisfactory given the application.

The second consideration is rod string loading. The maximum rod stress
summary output parameter indicates that the rod string would be only
moderately loaded at approximately 57% of yield. To examine rod loading in
more detail, select the Rod Loading/Deflection tab to bring up that output
window. The Chart pull-down list at the top of the window allows you to
display different results charts. The "Rod String Torque and Axial Load
Profiles" chart shows the loading profiles through the length of the rod string.
Maximum torque and axial load values almost always occur at surface in PC
pumping systems. This results in the maximum rod stress of approximately
333 MPa (57% of yield) also occurring near surface, as illustrated in the "Rod
String Effective Stress Profile" chart. The "Elastic Based Rod String Design"
chart shows elastic and deformation design factors throughout the length of
the rod string. The lower the design factor, the less likely a rod is to
experience a failure due to overloading.
In the "Torque Breakdown" charts, incremental torque due to contact is
evident along the length of the well. This is due to the contact loads that
develop between the rod string and the tubing in directional wells. Viscous
torque is negligible due to the low fluid viscosity (i.e. 100 cp). Other charts
include "Rod String Deflection and Rotation" as well as "Rod String Space
Out". When you select the "Rod String Space Out" chart, an optional Thermal
Effects window can be viewed by clicking the Specify Thermal Effects button. For
this session, ignore these effects and just click the OK button to return to the
"Rod String Space Out" chart shown below.

This chart displays rod deflection profiles due to both the rod weight as well as
operational loadings. At the bottom of the well, the operating deflection is the
minimum space-out required which is shown for this particular scenario to be
120.6 mm.
Another issue being considered is the rod/tubing contact loads. Within the
Summary tab, the maximum coupling contact load is displayed as 501 N. An
output message at the bottom of the window verifies that this
coupling/centralizer loading is excessive. By clicking the Rod/Tubing Contact
tab, you access additional contact loading information. The "Rod/Tubing
Contact Loads" chart indicates that this particular well would have coupling
contact loads of almost 500 N throughout the majority of the rod string.
Practice viewing the other charts which illustrate distributed loading, contact
components and contact locations.
The wear analysis module can be accessed by selecting on the Auxiliary
Analysis tab and then the Rod/Tubing Wear tab. You will first need to assign

wear coefficients to the elements that contact the tubing which, in this case,
are the couplings. To assign the default wear coefficients for steel, select the
rows that you wish to update, click on the Assign Wear Coefficients button, choose
the Steel Defaults radio button and click OK. Since there is no sand in this well,
the Sand Cut input box should contain a zero value. Click Calculate to complete
the wear calculation. Charts accessible from the wear window show that the
tubing wear rate in some parts of the well exceeds 240% per year (i.e. wear
through tubing wall in less than five months). Practice changing the wear
coefficients and sand cut value to assess the effects these parameters have on
wear rates.

Since it is usually recommended that coupling contact loads be kept below

220 N (50 lbs) to prevent excessive rod and tubing wear problems,
modifications will have to be made to the system configuration to correct this
problem.
Before you make changes to the rod string configuration, review the drive
equipment operating conditions. Summary output parameters show an energy
cost of $19.01 per day and a prime mover power output of 19.55 hp. Enter
the Drive Equipment results tab to examine the surface component loading in
more detail. Once in this window, use the tabs at the top to move between
screens showing detailed specifications for the drivehead, belts and prime
mover. When you select the Drivehead tab, it is apparent that the AVI-4-7/8
drivehead is undersized.
Its power output is high at 88.28% of the
maximum. The Prime Mover tab, which is shown below, indicates that the
motor is overloaded at 126%. To generate the required pump speed, the
prime mover would be operating at 934 RPM which corresponds to an
operating frequency of 47 Hz.
The current draw with the existing
configuration would be 31.9 A.

The analysis results indicate that your initial design produces unacceptable
rod/tubing contact loading and wear and overloading of the surface
equipment. Because the fluid properties and operating conditions are fixed,
you must overcome these problems through changes to the system
configuration.
To change the analysis inputs, click the Equipment
Configuration tab at the top of the window.
In order to address the undersized drive equipment, select the Surface Drive
Equipment update button.
Examination of the currently selected AV1-4-7/8
drivehead reveals that it only has a maximum power of 20 hp. Replace this

undersized drivehead with the larger capacity National-Oilwell AV2-9-1. Note

that its maximum power is 75.1 hp. To ensure that the prime mover has
enough power, adjust the Motor Power Rating to 30 hp. After completing these
modifications, click the OK button to accept the changes and move back to the
Equipment Configuration window.
A more difficult problem that needs to be corrected is the excessive rod/tubing
contact loading and wear rates. This problem can be addressed either by
changing the proposed horizontal well profile to lower the wellbore curvature
or by modifying the rod string configuration. Since a less aggressive well
profile would not be able to reach the desired target zone, the only option is to
solve the problem by modifying the rod string.
Click the Rod String update button and update the input fields by right-clicking
in the table and selecting "Select above inputs using this rod". Because
continuous rod is not an option in this application, the only method available
to reduce the rod/tubing contact loads along the wellbore is to add rod guides.
As before, begin by specifying the 22.2 mm Grade D standard rods with
22.2 mm API slimhole couplings (7.62 m length). In addition, select the
R&MES Pathfinder (22.2mm x 73.0mm) (SANGARD\T-180) rod guides which
attach rigidly to the rod body between couplings and spin with the rod body
(i.e. as opposed to spinthru guides where the rod rotates within the guide
body). Note that you also need to specify the number of guides per sucker
rod. The required number of rod guides is dictated by the well geometry and
operating conditions and ideally the placement should be done in a way which
limits the rod guide contact loads to an acceptable value. PCPUMP has a rod
guide optimization feature which can be used to help select the most
appropriate number of rod guides for each segment of the wellbore. To utilize
this feature, select Optimize number of guides under the Rod Guide Specification
section at the top of the window.
Specify a maximum allowable contact load per guide as well as the minimum
and maximum number of guides per rod. For this particular example, enter a
Maximum Contact Load of 220 N (50 lbs) and the values 0 and 5 for the
minimum and maximum Number of Rod Guides, respectively. Configure the
rod string in the normal manner by first clearing the old rod string and then
clicking the Fill to Surface button to enter the new rod string. Note that the rod
guide configuration in the spreadsheet initially appears in the format "Opt: ? x
R&MES (22.2mm x 73.0mm) (Rubber)". However, after you have performed a
calculation in the Analysis module, the "?" will be replaced with the optimized
number of rod guides.
With the rod string now reconfigured, close the Rod String Selection window
and obtain a new set of analysis results by clicking the Calculate button. Now

verify that the changes to the equipment configuration have eliminated the
design concerns identified in the previous analysis.
Because you did not change the pump, the calculated operating speed is the
same as before . However, the pressure loading has increased from 53.9% to
55.1% due to the slightly higher flow losses associated with the rod guides
(i.e. 353 kPa compared to the previous value of 244 kPa). Nevertheless, this
loading is still acceptable.
The next consideration is rod string loading. Since the rod size and grade are
the same, and the torque and axial load remained relatively constant, the
maximum rod stress changed slightly from 56.9% of yield to 50.5%. The
minimum space-out distance changed slightly to 124 mm.
A key issue of concern with the initial design was the high rod/tubing contact
loads.
To examine the results for this modified design, move to the
"Rod/Tubing Contact Loads" chart within the Rod/Tubing Contact output
window. This chart shows that the maximum contact load has been limited to
220 N per rod guide with the new configuration. Within this same window,
select the "Rod Guide Loading and Spacing" chart which is shown below.

This chart displays the average rod guide contact loads and number of guides
per rod. Note that the optimized configuration required between zero and
three guides per rod in order to limit the contact loads to the maximum value
specified. Note that no rod guides are added if the contact loading is less than
35% of the maximum allowable value specified in the Rod Guide Optimization
area.
Move back into the Rod/Tubing Wear analysis window under the Auxiliary
Analysis tab. There it can be seen that there is a large reduction in the amount
of wear compared to the case with no rod guides. Since the rod guides are
now in contact with the tubing, the wear coefficients must be adjusted
accordingly. Assign wear coefficients corresponding to Urethane Defaults for
the rod guides and Steel Defaults for the couplings that contact the tubing in
sections where no guides are present. Click Calculate. The tubing wear rate is
now 54% per year , almost 5 times less than the case with couplings. This
illustrates the advantage of limiting the rod guide contact loading.
The final consideration in this horizontal well design is the surface equipment.
Summary parameters reveal that the prime mover output power (17.2 hp) has
remained essentially the same as in the initial assessment. More importantly,
the previous output messages that indicated drivehead and prime mover

overloading no longer appear.

To confirm the adequacy of the surface
equipment design, take a look at the corresponding output window. With the
new AV2-9-1 drivehead, the overall power output has been reduced to only
21% of maximum. Similarly, the upgraded 30 hp electric motor is loaded at a
very reasonable 74%.
This reconfigured system addresses all of the original design issues.
Consequently, you can be assured that it satisfies the original requirements
provided that the operating conditions will not change dramatically.
Nevertheless, it is likely that further modifications could be made to the
wellbore profile and equipment configuration that would result in further
optimization. For practice, try making additional changes to the system
configuration to see if you can further improve the overall performance.

You are here: Sample Sessions > Session 3: Heavy Oil Well Conversion

Session 3: Heavy Oil Well Conversion

Note: The samples in this Help File are based on PCPUMP v3.4. If you are
using a later version of the program, or an updated database, some of the
results you get may not be the same. Also, some of the equipment selected in
this Help File may no longer be available in the database. If this is the case,
select the closest match available.
This sample session shows how PCPUMP might be used in assessing the
conversion of a heavy oil well from conventional beam pumping to a surface
driven PC pumping system. In doing so, it introduces equipment comparison
and pump comparison calculations. In addition, the session shows how to
input directional survey information, use the advanced viscosity mode and
view several additional output windows.

Scenario
A directional heavy oil well was originally brought on production using a
conventional beam pumping system.
However, high fluid viscosity and
significant sand production has led to numerous production problems. With
the existing beam pump, rod fall problems have limited the well's production to
18 m3/D at a fluid level of 450 Vm. It has been determined that this rate
could be increased to 25 m3/D, if the well could be pumped down to 600 Vm.

Objective
In an attempt to resolve these production problems and secure this
incremental production, this well will be converted over to a surface driven PC
pumping system. Select drive equipment (hydraulic based) and downhole
equipment that is appropriate for this particular application. It is preferable to
use the 22.2 mm DR round continuous rod from the existing beam pumping
installation. Important considerations include pump operation, rod string
loading, rod/tubing contact loads, tubing flow losses and surface equipment
operation.

Data
Wellbore Geometry
Well Type: Directional
System Configuration:

Pump Seating Depth: To be determined.

Mid-Perforations: 690 mKB
Casing: 177.8 mm x 34.23 kg/m
Tubing: To be determined.
Rod String: 22.2 mm Grade DR continuous rod (from existing installation)
PC Pump: To be determined.
Surface Equipment: To be determined (hydraulic based)
Fluid Properties:
Fluid Composition
Water Cut: 5%
Sand Cut: 3% by volume
Gas Specific Gravity: 0.7
Oil API Gravity: 10API
Water Specific Gravity: 1.05
Sand Specific Gravity: 2.70
Fluid Viscosity
Fluid Viscosity: Temperature versus viscosity data available
Operating Conditions:
Fluid Rate: existing = 18 m3/D, potential = 25 m3/D
Fluid Level: existing = 450 Vm, potential = 600 Vm
Tubing Head Pressure: 150 kPa
Casing Head Pressure: 0 kPa (vented)
Bottomhole Temperature: 22C
Temperature Gradient: 0.5 C /100 m

Procedure
In this session, you will select optimal:
downhole equipment (pump, tubulars, rods);
surface drive equipment; and
operating conditions.
In doing so, you need to consider the following issues:

pump operation;
rod string loading and space-out;
rod/tubing contact loads;
tubing flow losses; and
surface equipment operation.
The first step in this assessment is to input the directional survey data for the
well. Start PCPUMP and move into the Wellbore Geometry tab. For an existing
directional well, normally you must manually enter the directional survey
information directly into the table in the Table tab. Starting at surface, the
measured depth, hole angle and azimuth values are entered for each survey
station. As the data in entered the calculated parameters are automatically
updated.
If the directional survey data has been previously entered or is available in a
format which PCPUMP can read, it can be imported directly into the wellbore
geometry table. The survey file for the well being considered in this sample
session was included with the files shipped with the program. To import it,
click the Import button, select the file type '.wbr' and select the "samps3.wbr"
file from your default Wellbore file directory. The window will be updated with
the survey data and appear as shown below.

Using the Summary tab, you can establish that the well has a total measured
depth of 703.0 mKB, a total vertical depth of 623.0 Vm and a final hole angle
of 34.3.
Select the Charts tab to view the directional survey data graphically. By
selecting the Dogleg Severity chart, you can see the wellbore curvature
profile. Note that the dogleg severity is highest in the upper portion of the
well and tends to decline with depth. The maximum curvature of 4.5/30 m
occurs at a measured depth of about 93 mKB.
Now that the directional survey data is loaded, return back to the Equipment
Configuration tab to continue with the assessment.
In this sample, you will use the case manager to build different scenarios to
simultaneously assess a number of different pump models and sizes of
tubing. When setting up equipment cases, it is recommended that you initially
input the information that will be common to all cases. This base case can
then be duplicated and customized as required. Alternatively, a component of a
case can be dragged to another case within the case manager causing the

component information to be copied. In this session, the Analysis Comparison

mode will be used to examine the effect of different tubing sizes on system
performance. All of the other equipment will be considered common and be
specified first.
Start by entering the pump seating depth at 695 mKB and the mid-perforation
location slightly higher at 690 mKB.
Continue by specifying 700 m of 177.8 mm x 34.23 kg/m casing. Do not
select any tubing at this time, as this will be done later when you set up the
different equipment cases. To complete the downhole equipment selection,
add a complete string of 22.2 mm DR continuous rod in 10 m segments by
specifying the rod and clicking Fill to Surface.
Now move into the Surface Drive Equipment Selection window. For this heavy
oil application, assemble a configuration which includes a drivehead, hydraulics
and an electric motor. From within the Drivehead tab, select a Weatherford
(Canada) M2 model drivehead. The specifications displayed should reveal that
it has a 60 hp rating and contains a right angle gear box with a 2:1 reduction.
This unit was selected because the right angle configuration is convenient for
attaching hydraulics and the gearbox reduction is helpful in a low speed
application.
Next, move to the Hydraulics tab and check the Drive equipment includes hydraulics
box. This will allow you to select the hydraulic components. Using the dropdown lists, choose the Volvo F11-110 hydraulic motor and Sundstrand L38
hydraulic pump. After you choose these components, their specifications will
be displayed in the window.
Now advance to the Prime Mover tab. For this particular application, start by
specifying a motor power rating of 20 hp, 6 motor poles, a nominal motor
efficiency of 92% and a nominal power factor of 0.85. Leave the supply
frequency and voltage at their defaults of 60 Hz and 460 V. Finally, for pump
speed matching, select the adjust hydraulic pump displacement option. This
will cause the pump speed to be matched to the prime mover speed through
adjustment of the hydraulic pump displacement (i.e. via swash plate
alteration) and its associated speed reduction ratio. When you have finalized
your surface drive equipment, click OK to return to the Equipment
Configuration window.
Now move to the Fluid Properties tab. This session once again requires singlephase fluid properties and standard operating conditions. First, ensure that
single-phase fluid properties are active and select the Calculate Fluid Density
option. Enter the Oil API Gravity as 10API. Next enter the produced Water

Specific Gravity and Sand Specific Gravity of 1.05 and 2.70, respectively, and
the Water Cut and Sand Cut of 5% and 3%. Leave the tubing and casing
density factors at their default value of 1.00. The casing and tubing density
displays should both show values of 1032 kg/m3. Finish by specifying the Gas
Specific Gravity of 0.7. The Fluid Composition tab of the window will appear as
shown below:

As an alternative to specifying a single viscosity value, the Advanced Viscosity

option in the Fluid Viscosity tab allows you to define the effects of temperature,
non-Newtonian behavior and produced water on fluid viscosity. To access the
Advanced Viscosity section, select Use Advanced Viscosity. The window shown
below will appear.

In heavy oil applications, the dependency of viscosity on temperature can have

a significant influence on PC pumping system performance. This session
demonstrates how PCPUMP can be used to take these effects into consideration
by allowing the user to define the relationship between fluid viscosity and
temperature. To do this, start by checking the Specify Temperature Effects box.
Then, enter the following temperature versus viscosity data into the table:
Temperature

Viscosity

20C

3700 cp

30C

1050 cp

40C

400 cp

50C

205 cp

To view the relationship graphically, switch to the Charts tab and select the
"Temperature Effects on Viscosity" chart from the drop-down list. The chart
should appear as shown below.

As long as Advanced Viscosity is active, fluid viscosity will be determined based

on the criteria defined within the window. In this particular example, fluid
viscosity will be calculated along the length of the tubing based on the
bottomhole temperature, temperature gradient and viscosity versus
temperature relationship specified.
Next, begin the process of specifying operating conditions by selecting the
Operating Conditions tab and selecting the radio buttons corresponding to the
Produced Fluid Flow Rate and Fluid Level. For design purposes, it is best to start by
evaluating the most severe operational scenario. In this sample session, this
occurs with the potential fluid rate of 25 m3/D and fluid level of 600 Vm.
Enter these values into their appropriate edit boxes along with the tubing head
pressure of 150 kPa, casing head pressure of 0 kPa, bottomhole temperature of
22C and temperature gradient of 0.5C/100 m. The operating conditions
input area should appear as shown below.

Now that the common inputs have been entered, you need to create several
equipment cases that use different tubing and pump combinations. Equipment
cases can be created by right-clicking in the Case Manager area and selecting
"Add Case". Alternatively, an existing case can be duplicated by right-clicking
on the existing case and selecting "Copy Case". To rename a case, right-click
on the name and select "Rename Case". For this session create 9 copies of the
existing case and rename them based on the following list:

Name

73 Tubing
Pump

Tubing Size (API)

10-600 73.0
mm
9.7 kg/m

73 Tubing | 28-900
Pump

73.0
mm
9.7 kg/m

73 Tubing | 42-1200 73.0

mm
Pump
9.7 kg/m

88.9 Tubing | 10-600 88.9

mm
Pump
13.8 kg/m

Weatherford (BMW)
Pump

10-600

28-900

42-1200

10-600

88.9 Tubing | 28-900 88.9 mm x

Pump
13.8 kg/m

28-900

88.9 Tubing | 42-1200 88.9

mm
Pump
13.8 kg/m

114.3 Tubing | 10-600 114.3

mm
Pump
19.0 kg/m

114.3 Tubing | 28-900 114.3

mm
Pump
19.0 kg/m

114.3 Tubing | 42-1200 114.3

mm
Pump
19.0 kg/m

42-1200

10-600

28-900

42-1200

For each case select the appropriate tubing size and Weatherford (BMW)
pump. For simplicity, leave the static pump friction and volumetric efficiency
values at the Preferences defaults of 100 Nm and 90%, respectively. The
Equipment Configuration window should appear as shown below.

These new equipment cases can then be configured independently as

required.
Note, however, that any changes made in the Equipment
Configuration window only apply to the currently active case. You can switch
between existing equipment cases by selecting their names within the Case
Manager area.
You should now have nine cases which have different tubing
sizes and different pumps. When you switch between these equipment cases,
the tubing and pump specifications displayed in the main window will change
accordingly. With the system configuration and analysis inputs specified, you
can now start to perform assessments. Click the Calculate button to execute the
analysis.
From a review of the results in the Analysis Summary tab for the first
configuration you will discover several problems. Output messages indicate
that the pump pressure rating is being exceeded (159% of rated) and the
required hydraulic pump displacement exceeds the maximum. To examine the
pressure profile in more detail, select the Basic Fluid Flow tab. The "Pressure

Profiles" chart displays the pressure in the casing/tubing annulus and

production tubing. Note that the pressure in the tubing above the pump is
over 10,000 kPa. Switch to the "Tubing Pressure Components" chart to see
the components which make up the tubing pressure profile. The chart shown
below reveals that the flow losses are of a similar magnitude as the hydrostatic
head as shown below.

Move to the "Temperature and Viscosity Profiles" chart which shows that fluid
viscosity is quite high, ranging from 2740 cp at the pump to 4400 cp at
surface. The large flow losses can be attributed to the high viscosity fluid and
to the relatively small flow area of the 73.0 mm tubing.
Now compare the first case to the remaining cases by using the comparison
table or flipping through the cases using the case manager. In this analysis,
lets look at the comparison table.

This table provides a tabular display of the results for each of the cases
selected. The rows correspond to individual scenarios and the columns display
the input conditions or results for several key operating parameters. Use the
scroll bars to examine all of the information in the table. Notice that the flow
losses drop from 3668 kPa with the 73.0 mm tubing to 350 kPa with the larger
114.3 mm tubing. Similarly, many of the other parameters such as the energy
costs, polish rod power, maximum rod torque and pump pressure loading also
decrease. This is a reflection of the significant effect that flow losses can have
on PC pumping system performance.
In the lower portion of the Table tab of the Analysis Comparison output
window, a summary of the system configuration for the currently active case is
displayed. You can change the active case by highlighting its row in the table.
Make the "114.3 mm Tubing" the active case and examine the summary
information. Next, close the Analysis Comparison window. Reexamine the
charts in the Basic Fluid Flow output window to see that the flow loss
component of the tubing pressure profile has been reduced considerably with
the larger tubing.
Now that you have established that 114.3 mm tubing will keep the tubing flow
losses to an acceptable level, consider the other design issues. If you examine
the output messages for the 114.3 mm tubing and 10-600 pump analysis,
there are still warnings related to the hydraulic pump displacement and pump
pressure loading.
Both of these are a consequence of the small

displacement/low pressure rating of the 10-600 pump used in this

assessment. Note that the pump is listed as operating at a speed of 278 RPM,
which would typically be considered excessive for a high viscosity heavy oil
application.
For the remaining two pumps, the operating speeds are 66 and 99 RPM and
the pump pressure loading is 50%-70%. Although the maximum rod stress
increases with the larger displacement pumps, it only reaches 70% of yield in
the worst case scenario.
Similarly, continuous rod/tubing contact loads
increase with the larger displacement pumps but remain within an acceptable
range for all cases. Because both pumps (28900 and 421200) are producing
the same fluid rate, the flow losses are all similar: 350 kPa.
Although either pump will likely suffice for the proposed application, you want
to choose the one which will produce the best overall system performance (i.e.
costs must also be considered). From an operational standpoint, the 421200
model is likely the best choice because they result in the lowest rod string
stresses and rod/tubing contact loading. Looking at economics, the 28900
model is preferable since it has the lowest displacement and pressure rating
and consequently will likely be the least expensive.
Close the Analysis Comparison output window and select the "114.3 mm
Tubing - 28-900 Pump" case. The analysis Summary tab should appear as
shown below.

With the pump operation, rod string loading, rod/tubing contact loading and
tubing flow loss considerations addressed, the only remaining issue is the
operation of the surface drive equipment. Summary parameters reveal that
the energy cost is $6.76 per day and the prime mover output power is 7 hp.
More importantly, within the Output Messages area the warnings of hydraulic
problems no longer appear. The only output messages remaining indicate that
the hydraulic pump displacement has been adjusted to 49% of its maximum to
match the pump speed, and that 5.36% of the pump differential pressure is a
result of flow losses. To confirm the surface equipment design, move into the
Drive Equipment output window. The Weatherford (BMW) M2 drivehead is
lightly loaded at 8.9% of its maximum power output. The hydraulics also
appear to be adequate, with the motor and pump operating at 35% and 69%
of their maximum pressures, respectively. Finally, the 20 hp prime mover is
listed as drawing 8.32 A of current and being loaded at only 35% of its rated
power.
The primary objective of this session was to illustrate how running multiple

cases can be used to compare different system configurations efficiently. The

ability to complete comparative assessments of numerous options quickly can
be invaluable when trying to determine the best configuration for a particular
application. However, the optimization process will occur much faster when
the user has a clear understanding of the basic interactions between system
parameters (e.g. equipment, fluid properties and operating conditions) and
output results (e.g. tubing flow losses, rod torque).

You are here: Sample Sessions > Session 4: Well Production Optimization

Session 4: Well Production Optimization

Note: The samples in this Help File are based on PCPUMP v3.4. If you are
using a later version of the program, or an updated database, some of the
results you get may not be the same. Also, some of the equipment selected in
this Help File may no longer be available in the database. If this is the case,
select the closest match available.
This fourth sample session will illustrate how PCPUMP might be used to
evaluate the optimization of production from a high water cut well. The
session continues to build on concepts from the previous sessions and
introduces advanced (inflow performance) operating conditions, pump test
information input, batch comparison calculations and more output windows.

Scenario:
A vertical well equipped with a surface-driven Weatherford (Griffin) 95-1040
pump is operating at about 200 RPM and producing 160 m3/D of fluid with a
91% water cut. However, IPR data from an earlier well test indicates that
there is potential to increase the production rate if the well can be pumped
down.

Objective:
Determine how far the well can be pumped down before the limits of the
existing configuration will be exceeded. Establish which component will be the
"weak link" in the system. Important considerations include pump operation,
rod string loading, surface equipment operation and total system efficiency.
Note that in order to accurately model pump performance, data from a pump
test run prior to its installation should be considered.

Data:
Wellbore Geometry
Well Type: Vertical
System Configuration:
Pump Seating Depth: 760 mKB
Mid-Perforations: 750 mKB
Casing: 139.7 mm x 23.07 kg/m

Tubing: 73.0 mm x 9.7 kg/m

Rod String: 22.2 mm Grade D standard rods with slimhole couplings (7.62
m length)
PC Pump: Weatherford (Griffin) 95-1040
- displacement = 0.950 m3/D/RPM
- pressure rating = 10208 kPa
- pump test data available
Surface Equipment: Oil Lift Technology Inc. 2000
Surface Equipment:
- Oil Lift Technology Inc. 2000
- No belt reduction (i.e. 1:1) and 97% efficiency belt system
- 50 hp, 6 pole electric motor (efficiency=92%; power factor=0.85)
Fluid Properties:
Fluid Composition
Water Cut: existing = 89%; optimized = to be determined
Sand Cut: 0% by volume
Gas Specific Gravity: 0.7
Oil API Gravity: 30 API
Water Specific Gravity: 1.00
Sand Specific Gravity: 2.70
Fluid Viscosity
Fluid Viscosity: Temperature versus viscosity data available
Operating Conditions:
Fluid Rate: existing = 160 m3/D; optimized = to be determined
Producing Pressure: existing = 3136 kPa; optimized = to be determined
Tubing Head Pressure: 250 kPa
Casing Head Pressure: 50 kPa
Bottomhole Temperature: 30C
Temperature Gradient: 0.5 C /100 m

Procedure
In this session, you must carry out a sensitivity analysis to investigate the
effects that pumping the well down will have on the system performance.

Based on results from this assessment, you can establish the limit for the
existing system configuration and determine which components will need to be
modified for further optimization.
Consider the following issues:
pump operation;
rod string loading and space-out;
surface drive equipment operation; and
overall system efficiency.
Begin by starting PCPUMP and specifying the equipment configuration (since it
is a vertical well, ignore wellbore geometry). Enter the Pump Seating Measure
Depth of 760 mKB and Mid-Perforations Measured Depth of 750 mKB.
Next, open the Pump Selection window, select the Weatherford (Griffin) 951040 pump and make it active. Specifications displayed on the screen should
indicate that the pump has a nominal displacement of 0.950 m3/D/RPM and a
pressure rating of 10208 kPa. In the previous sample sessions, you specified
static parameters for pump friction and volumetric efficiency. For this session,
actual pump bench test information will be entered so that friction and
efficiency values can be calculated dynamically based on the operating
conditions. To access the Pump Test Information window, select Specify Test Data
and click on the Specify button. Within the window that appears, you can input,
process, view and save pump test information.
At the top of the Pump Test Information window, the currently active
Weatherford (Griffin) 951040 model is listed. The Pump Test Name dropdown list displays all of the pump tests associated with this pump and stored in
your default pump test directory. Note that unless you have previously
entered pump tests for the 951040 pump, this list will be empty. Create a
new pump test by clicking the Create File button. In the dialog box that appears,
enter the Pump Test Name as "Sample Session #4" and then click the OK
button. You can now proceed to input pump test data into the table in the
Data tab. For each test point, enter a pump speed, differential pressure, total
torque and volumetric efficiency. For this session, specify the following test
data:
Pump Speed Differential Pressure

Total Torque

Volumetric Efficiency

100 RPM

94 Nm

101.3%

0 kPa

100 RPM

2449 kPa

324 Nm

97.0%

100 RPM

4897 kPa

584 Nm

55.0%

100 RPM

7346 kPa

821 Nm

2.8%

150 RPM

0 kPa

147 Nm

96.5%

150 RPM

2449 kPa

342 Nm

92.7%

150 RPM

4897 kPa

579 Nm

70.6%

150 RPM

7346 kPa

859 Nm

32.8%

200 RPM

0 kPa

129 Nm

99.3%

200 RPM

2449 kPa

324 Nm

96.6%

200 RPM

4897 kPa

583 Nm

78.8%

200 RPM

7346 kPa

864 Nm

55.9%

As you enter the above values, the output parameters will automatically be
calculated. Once you have finished entering the above inputs, the screen
should appear as shown below.

The right-hand portion of the table in the Pump Test Information window is
filled with calculated parameters. For each test point, the fluid rate, the fluid
slippage, adjusted volumetric efficiency, hydraulic torque, friction torque,
effective power, actual power and total efficiency will be displayed.
If
necessary, use the horizontal and vertical scroll bars to move about the table
in order to access the full range of data.
In addition to these table

parameters, the list box in the lower portion of the screen contains a number
of summary values. These include pump pressure rating, nominal pump
displacement, actual pump displacement, average friction torque and
volumetric efficiency at pump pressure rating. A detailed discussion on pump
testing and the method which PCPUMP uses to process the data is included
elsewhere in the Help File under Pump Test Information.
You can also examine the pump test information graphically by selecting the
Chart tab. Using the Chart drop-down list, try changing the chart display
between the ten different types available.
The Pump Test Information window also permits you to calculate performance
characteristics at a Target Pump Speed and Target Differential Pressure.
Within the Data tab, enter values of 400 RPM and 8927 kPa into the edit
boxes, respectively. A new data point which represents your target conditions
will be added at the bottom of the table. In addition, most of the charts will
also contain an additional data series which corresponds to the target
conditions.
Move back to Chart tab and view the "Fluid Flow Rate vs
Differential Pressure" chart. It should appear as shown below.

Once you have finished inputting the test data click the OK button to confirm
your pump test selection and return to the main Pump Selection window. Your
pump test will now be associated with the currently selected pump. Close the
Pump Selection window and return to the Equipment Configuration window.
Continue by specifying 800 m of 139.7 mm x 23.07 kg/m casing and 760 m of
73.0 mm x 9.7 kg/m tubing. Finish the downhole equipment selection by
adding 22.2 mm Grade D standard rods with 22.2 mm API slimhole couplings
(7.62 m length).
Now move into the Surface Drive Equipment Selection window and toggle the
check-box to the active state.
Recall that the existing configuration is
comprised of a drivehead, belts and an electric motor. Select the Oil Lift
Technology Inc. 2000 drivehead, 1:1 belt reduction (i.e. no reduction) at 97%
efficiency and a 50 hp (6 pole) electric motor with nominal efficiencies and
power factors of 92% and 0.85, respectively.
Finally, for pump speed
matching, select the adjust prime mover speed option. When you have
finalized surface drive equipment selection, click the OK button to return to the
Equipment Configuration window which should appear as shown below.

Proceed on to the Fluid Properties tab. Single-phase fluid properties will once

again be utilized. Set the Water Cut to 89%, and the Sand Cut to 0%. For
simplicity, because the well is producing primarily water, enter casing and
tubing fluid densities of 1000 kg/m3. Continue by specifying a Gas Specific
Gravity of 0.7 and in the Fluid Viscosity tab, enter a fluid viscosity of 1 cp.
When completed, the fluid properties input area should appear as below.

Next, move to the Operating Conditions tab to enter the operating conditions.
Normally, it is recommended that you input the IPR data first if available. This
is done using the IPR window which is accessed by checking the Specify IPR data
box at the top of the window and then clicking on the Specify button. Within
this window, you can select from among several common IPR types. For this
session, choose the Standard Composite relationship and then enter the following
test data:
Static Reservoir Pressure: 7000 kPa
Bubble Point Pressure: 5000 kPa
Test Point #1-Producing Pressure: 4000 kPa
Test Point #1-Fluid Rate: 125 m3/D
Test Point #1- BS&W Content: 88%
The window should appear as shown below.

On the right-side of the dialog, a chart shows producing bottomhole pressure

as a function of fluid rate and extends from zero flow rate (producing pressure
= static reservoir pressure) to the maximum flow rate (producing pressure =
zero). Because you have utilized a Composite IPR type, the chart also
contains curves for oil and water rates as well as the water fraction.
Within the IPR window, you can explicitly calculate producing pressures at a
target fluid rate or vice versa. To do this, select the desired target condition
(pressure or rate) by enabling its toggle button, enter your target value into
the corresponding edit box. With the existing IPR data, if you enter a
producing pressure of 500 kPa, a fluid rate of 262.6 m3/D is calculated. Once
you have specified your IPR, click the OK button to return to the Operating
Conditions window.
Next enter values for the operating condition parameters. Start by selecting
the Produced Fluid Flow Rate as an input parameter. For the initial assessment,
enter the existing fluid rate of 160 m3/D. Complete the specification of

operating conditions by entering the Tubing Head Pressure of 250 kPa, Casing
Head Pressure of 50 kPa, Bottomhole Temperature of 30C, and Temperature
Gradient of 0.5C/100 m. When complete, the Operating Conditions window
should appear as shown below.

You are now ready to begin performing assessments. Before you look at
production optimization, it is important to assess the results for the existing
equipment and current operating conditions which were specified. Click the
Calculate button. The analysis Summary tab should appear as shown below.

The results based on the IPR data indicate that at the specified fluid rate of
160 m3/D, the associated producing pressure (i.e. pressure at midperforations) would be 3136 kPa.
To facilitate examination of the fluid conditions at important well locations,
PCPUMP provides a Key Locations output window. To access this window, select
the Key Locations tab and the window shown below will appear.

The Key Locations output window contains a table with each row corresponding
to key well locations and each column listing values for a key parameter at the
respective locations. In the current case, the mid-perforations are listed with
a vertical depth of 750 m, a temperature of 30C, a viscosity of 1 cp and a
pressure of 3136 kPa. In order to generate this bottomhole or producing
pressure, the table indicates that the gas/liquid interface (i.e. fluid level)
would have to be located at a vertical depth 435.9 m. Examine the values at
the other key locations listed in the table. Note that parameters that are
marked as "N/A" are either not applicable at that location or do not have any
meaning for single-phase fluid properties (e.g. tail joint intake). When you
have reviewed the Key Locations output window, return to the analysis
Summary tab.
Using the existing operating conditions as a starting point, you need to
evaluate the potential for achieving increased production rates by lowering the
producing pressure. Look first at pump operation, the volumetric efficiency
has been calculated to be 88.65% using the pump test data. On the basis of
this efficiency and the current fluid rate, the pump speed is 191.85 RPM.
Pump pressure loading is moderate at 44.47% of its rated value. Overall, at
the existing operating conditions, the pump is operating acceptably well. Both
higher speeds and increased pressure loading can be tolerated.

Other considerations are rod string loading and space-out. The maximum rod
stress output parameter indicates that the rod string is currently loaded at
78.33% of yield. Consequently, it still has the potential to accept slightly
increased loading. Move to the Rod Loading/Deflection output window to see
that the minimum space-out distance for the existing operating conditions is
151.4 mm.
Next, examine drive equipment operation by moving into the Drive Equipment
output window. The drivehead is relatively lightly loaded at approximately
16% of its maximum power and 41% of its maximum speed. The electric
motor is only loaded at 56% of its rated power. The current draw with the
existing configuration is displayed as 33.34 A.
The final consideration is overall system efficiency. This can be viewed in the
Summary tab and under the System Efficiency section of the Output
Parameters area. For the existing conditions, the system mechanical/electrical,
system overall, and pump volumetric efficiencies are 71.98%, 59.97% and
83.32%, respectively.
To look at the system efficiency in more detail, move to the Energy Flow tab.
This window, shown below, traces the flow of power through the individual PC
pumping system components.

Using this Energy Flow output window you can determine where power is being
utilized and isolate any components which have undesirable efficiencies. With
the existing configuration, the drive equipment components and the rod string
all have relatively high efficiencies. Note that the Overall System Mechanical
Efficiency shown does not consider the inefficiencies related to fluid slippage in
the pump. The pump efficiency shown considers only losses due to pump
friction.
Based on the existing conditions, it appears that there is potential to increase
production rates by pumping the well down. To evaluate changes that might
be considered to achieve optimization, you can use the Batch Analysis tool.
This tool allows a series of assessments to be performed for a specified range
of fluid properties or operating conditions.
To carry out this type of
assessment, check the Perform Batch Analysis box in the Batch Parameter area
under the Case Manager. Then click on the update button
to the right of the
Parameter field which will bring up the Batch Parameter window shown below.

Because in this session you are trying to evaluate the effects of pumping the

well down, select "Bottomhole Pressure" as the batch Parameter from the
check-list and click the column that appears in the table. Next, define the
values for which the evaluation will be completed. This can be done either
automatically with fixed increments, or manually.
To define values
automatically, enter a starting value, an increment and a number of rows.To
define discrete values of producing pressure, you can type the desired values
into the table.
For this session, evaluate the well for bottomhole pressures ranging from the
existing value of 3136 kPa to a nearly pumped off condition. This can be done
effectively by using the automatic feature and entering values of 250 kPa and
3500 kPa for the start and end conditions and specifying an increment of
250 kPa with 14 rows. Once you have finalized your input, click the OK button
on the bottom of the window to start the computational process.

To start the analysis, click on the Calculate button and a progress bar will display
the status of the calculation. When the resulting 14 different scenarios have
been analyzed, the Chart tab of the Analysis Comparison output window will be
as shown below.

The comparison Chart output window provides a graphical display of the effects
that changes in the selected batch parameter have on system performance.
The window contains a chart with the batch parameter displayed on the x-axis
over the specified range of values. The Chart drop-down list at the top of the
tab allows you to change the chart to display different system parameters on
the y-axis.
Move among these charts and examine how the different
parameters change with producing pressure. As the well is pumped off (i.e.
the producing pressure decreases), the fluid rate increases. Note that at a
close to pumped off condition of 250 kPa, the rate has increased to 272 m3/D
from 160 m3/D under the existing conditions. This results in corresponding
increases in the pump speed which reaches nearly 400 RPM. Notice that the
pump volumetric efficiency decreases to approximately 73% as the well is
pumped off. This is the result of lower producing pressures creating higher
pump pressure loading and consequently lower volumetric efficiencies (i.e.
based on the pump test information).
Now use the comparison charts to investigate the effects of changes that can
be made to optimize production on the important operational issues. The first
of these considerations is pump operation. You have already established that
under a nearly pumped off condition, the pump speed would be about 400 RPM

and the volumetric efficiency 73%. A review of the pump pressure loading
chart reveals that in the worst case scenario, the pump would be operating at
approximately 76% of its rated pressure. Overall, these parameters all fall
within an acceptable range and indicate that pump operation would not be an
issue.
A second consideration is rod string loading. Both torque and axial load
increase as the well is pumped off. This results in the maximum rod stress
increasing to over 121.9% from a value of 80% under the existing conditions.
If you consider a reasonable limit for the maximum allowable rod stress to be
90%, this would occur at a producing pressure of 2500 kPa (i.e. fluid rate of
185 m3/D). In order to increase the production rate further, the rod string
would have to be upgraded from its existing 22.2 mm Grade D configuration.
Note that space-out allowances should also be taken into consideration as the
well is pumped off. Given that the rod string axial load increases due to higher
pump differential pressure as the fluid level decreases, the original space-out
allowance may become inadequate at lower fluid levels.
Another consideration is drive equipment operation. The prime mover output
power is shown as increasing to 53 hp at the nearly pumped off condition.
With the existing, 50 hp electric motor, this represents a slight overloading
condition.
The final consideration is overall system efficiency. From the comparison
chart, it is evident that this value decreases from 60.0% at the existing
conditions to 57% in the nearly pumped off condition. Nevertheless, this
value still represents an acceptable efficiency for an artificial lift system.
Using the Batch Analysis comparison calculation mode you have evaluated the
effects of pumping the well down from its current producing pressure of
3136 kPa to a nearly pumped off condition (250 kPa). The analysis showed
that the rod string was the primary obstacle preventing operation at the
pumped off condition. Using the existing equipment configuration, the well
could be operated at a producing pressure of 2500 kPa which corresponds to a
fluid rate of 185 m3/D or a 19% productivity improvement. However, at lower
pressures the rod string stresses would exceed the recommended maximum of
90% of the yield strength.
If this "weak link" in the system was upgraded you could ideally pump the well
down considerably further.
To evaluate this option, move back to the
Equipment Configuration window and change the rod string configuration to
25.4 mm Grade D standard rods (7.62 m) with slimhole couplings. Then rerun
the Batch analysis.

A review of the results shows that in the worst case scenario, the rod string
stresses are now only about 83% of yield. You also need to check the surface
equipment which was previously highly loaded under pumped off conditions.
To do this, move to the "Prime Mover Output Power" chart shown below.

Notice that when the well is close to pumped off, the output power exceeds the
50 hp rating of the electric motor and drivehead. To avoid surface equipment
overloading, the maximum prime mover output power should be limited to
50 hp. Interpolations based on the comparison chart indicate that this could
be achieved by limiting the well draw down to a producing pressure of no lower
than 500 kPa.
To confirm this conclusion, return to the Operating Conditions tab, input a
Bottomhole Pressure of 565 kPa and re-calculate the case. The analysis output
Summary tab should appear as follows.

To quickly confirm that the design is adequate, note the absence of warnings in
the output messages box. A more detailed examination reveals that the fluid
rate is 260.1 m/D, which represents an improvement of 63% over the
existing production conditions. If you switch to the Key Locations output tab,
you will see that the gas/liquid interface (i.e. fluid level) is located at 698.1
mKB, which is equivalent to about 62 m of fluid above the pump intake.
Moving back to the Summary tab, the results show the pump will be operating
at a speed of 373.14 RPM with a pressure loading of 72.3%. Rod string
loading is 79.69% of the maximum yield stress.
In terms of surface
equipment operation, the prime mover output power is 47.69 hp, which is at
the rating of the electric motor and well under the rating of the drivehead.
In conclusion, the assessment indicates that with the larger 25.4 mm rods, the
well could be pumped down to 698 mKB. Further optimization would require a
larger motor and the installation of a pump with a higher pressure rating.
This sample session has illustrated how the Batch Parameter comparison
analysis mode can be used to quickly evaluate the consequences of
implementing changes to the operating conditions of a well. By evaluating the
system for an entire range of a particular operating parameter, it is easy to
identify both the onset of production-related problems as well as equipment
limitations corresponding to the conditions specified.

You are here: Sample Sessions > Session 5: Conventional Oil Application

Session 5: Conventional Oil Application

Note: The samples in this Help File are based on PCPUMP v3.4. If you are
using a later version of the program, or an updated database, some of the
results you get may not be the same. Also, some of the equipment selected in
this Help File may no longer be available in the database. If this is the case,
select the closest match available.
This sample session will illustrate how PCPUMP might be used to troubleshoot a
conventional oil well experiencing operational problems due to gas
interference. The session reinforces concepts from the previous sessions and
introduces multiphase fluid properties, tail joints and other output windows.

Scenario:
A vertical well equipped with a Kudu Industries 200TP1200SL pump is
currently producing to surface 80 m3/D of 38API oil, 20 m3/D of water and a
significant volume of gas. To generate these rates, the pump is operating at a
speed of over 500 RPM. Based on the surface liquid rate, this equates to a
volumetric efficiency of less than 40%. It is suspected that the low pump
efficiency is being caused by gas interference at the pump intake.
Measurements of the gas produced through the casing and tubing, indicate
that the producing GOR is approximately 20 m3/m3. The PC pump is seated at
965 mKB, uphole of the perforations which span from 997 mKB to 1003 mKB.
A casing patch located from 970 to 980 mKB prevents the pump from being
seated any lower.

Objective:
The low volumetric pump efficiency associated with the current operating
scenario yields high power costs and may result in a shortened pump life.
Assess the existing system configuration and operating conditions to verify
that gas interference is the likely cause of the low pump efficiency. Evaluate
the effectiveness of adding a tail joint positioned with its intake below the
perforations. Try finding a different pump model that can be run through the
casing patch restriction. The primary objective is to improve pump volumetric
efficiency and lower power costs. Other issues such as pump pressure loading,
rod stress, and surface equipment operation should also be considered.

Data:
Wellbore Geometry

Well Type: Vertical

System Configuration:
Pump Seating Depth: 965 mKB
Mid-Perforations: 1000 mKB
Casing: 139.7 mm x 23.07 kg/m (Patch from 970 to 980 mKB with
100 mm drift)
Tubing: 73.0 mm x 9.7 kg/m
Rod String: 22.2 mm Grade D standard rods with slimhole couplings (7.62
m length)
PC Pump: Kudu Industries 200TP1200SL
- displacement = 0.395 m3/D/RPM
- pressure rating = 12000 kPa
- friction torque = 100 Nm
- volumetric efficiency = ~40% (based on surface liquid rate)
Surface Equipment: Oil Lift Technology Inc. 2000
Surface Equipment:
- GrenCo Industries Ltd. D-2000-6E drivehead
- 2:1 reduction and 97% efficiency belt system
- 30 hp, 6 pole electric motor (h=92%; pf=0.80)
Fluid Properties:
Fluid Composition
Oil API Gravity: 38 API
Water Salinity: negligible
BS&W Content: 25%
Gas Specific Gravity: 0.8
Producing GOR: 20 m3/m3
Free Gas Separation: 30% (natural separation)
Fluid Viscosity
Fluid Viscosity: Temperature versus viscosity data available
Operating Conditions:
Fluid Rate: 80 m3/D
Fluid Level: 900 mKB

Tubing Head Pressure: 500 kPa

Casing Head Pressure: 150 kPa
Bottomhole Temperature: 35C
Temperature Gradient: 0.6 C /100 m

Procedure
In this session, you will evaluate:
the existing configuration;
the existing configuration with a tail joint added; and
an alternative configuration with a smaller diameter pump.
The following issues need to be examined:
pump volumetric efficiency;
power costs;
pump pressure loading;
rod string stresses; and
surface drive equipment operation.
Begin by starting PCPUMP and specifying the system configuration. Since it is
a vertical well, ignore wellbore geometry and enter the Pump Seating
Measured Depth of 965 mKB and Mid-Perforations Measured Depth of
1000 mKB.
Next, open the Pump Selection window and select a Kudu Industries
200TP1200SL pump. Leave the static pump friction and volumetric efficiency
values at the Preferences defaults of 100 Nm and 100%, respectively. Make
the pump active and confirm that its outside diameter will not fit through the
105 mm drift of the casing patch. Close the Pump Selection window to return
to the Equipment Configuration window.
Continue by specifying 1020 m of 139.7 mm x 23.07 kg/m casing and 965 m
of 73.0 mm x 9.7 kg/m tubing. Finish the downhole equipment selection by
adding 22.2 mm Grade D standard rods with 22.2 mm API slimhole couplings
(7.62 m length).
Now move into the Surface Drive Equipment Selection window and toggle the
check-box to an active state. Specify a GrenCo Industries Ltd. D-2000-6E
drivehead, 3:1 belt reduction at 97% efficiency and a 30 hp (6 pole) electric

motor with nominal efficiencies and power factors of 92% and 0.80,
respectively. Finally, select the adjust prime mover speed matching option and
click the OK button to return to the Equipment Configuration window. It should
appear as shown below.

Proceed to the Fluid Properties tab. The higher gravity oil and produced gas
volumes make this well ideally suited for a multiphase flow assessment. To
carry out this type of analysis, begin by switching the input area to multiphase
fluid properties. You can then enter the Oil Gravity of 38API, Water Salinity
of 0 ppm, Gas Specific Gravity of 0.80, BS&W Content of 25%, Producing GOR
of 20 m3/m3, values. The final input, Free Gas Separation, refers to the
percentage of free gas at the pump or tail joint intake that is separated and
diverted up the casing/tubing annulus. For this session, specify a value of
30% which is on the low end of the values typically attributed to natural
separation45. When completed, the multiphase fluid properties input area
should appear as below.

Next, move to the Operating Conditions tab and ensure that the Produced Fluid
Flow Rate and theFluid Level are selected as inputs. The pump speed is
determined based on the pump displacement, the intake volumetric efficiency
and the fluid throughput at the pump intake. However, the compressible
nature of multiphase fluids results in the same mass of fluid occupying
different volumes depending on the pressure and consequently location in the
pumping system. As a result, the calculated volumetric pump efficiency will
vary depending on the fluid rate used. Normally, volumetric efficiencies are
calculated based on the liquid rates at surface. Within PCPUMP, the efficiency
calculated in this manner is designated as the "Apparent Volumetric
Efficiency". When free gas is present at the pump intake, this value can
become quite low. If there is no free gas at the pump intake, then the
apparent and intake volumetric efficiencies will be similar in magnitude. The
significance of these two efficiency designations will be demonstrated in the
analysis results.
Enter the Produced Fluid Flow Rate of 80 m3/D, Fluid Level of 900 mKB, Tubing
Head Pressure of 500 kPa, Casing Head Pressure of 150 kPa, Bottomhole
Temperature of 35C and Temperature Gradient of 0.6C/100 m.
The
Operating Conditions window should then appear as shown below.

Next click the Calculate button. The analysis Summary tab should appear as
displayed below.

An initial review of the results reveals eleven output messages. Three of

these are directly related to gas interference. The first message indicates that
there is 62% free gas present at the pump intake. A second message confirms
the situation, by stating that the apparent volumetric efficiency is 37%.
Another message indicating a high pump speed of 542.62 RPM is the result of
the free gas comprising a large percentage of the fluid volume entering the
pump intake. Other messages state that the electric motor speed has been
adjusted to 1628 RPM to match the pump speed, that the electric motor power
rating is being exceeded at 120%, and that the flow losses make up 1.21% of
the pump differential pressure.
To examine the multiphase flow conditions in more detail, switch to the Key
Locations tab. Notice that values are displayed for free gas rate, free gas
percent and solution GOR, unlike in the single-phase assessments where they
were displayed as "N/A". At the mid-perforations, the fluid rate is listed as
240 m3/D with 158.3 m3/D (65.97%) of that rate being comprised of free gas.
The presence of free gas at the perforations is also evident from the solution
GOR at this location. Of the total producing GOR of 20 m3/m3, only 2.7 m3/m3
remains in solution at the perforations.
Notice that there are two rows labelled "Pump Intake" in the Key Locations
table. The table is divided into two sections, the lower section refers to the
casing and the upper section is for the tubing. For the pump intake (or tail
joint/shroud intake, as appropriate), the line in the casing section of the Key
Locations table refers to the flow before the gas is separated (i.e. it refers to
the total amount of free gas), while the line in the tubing section refers to the
flow that goes through the pump. Notice that both lines have the same oil flow
rates; it is the gas rates that are different: 189.6 in the casing and 132.7 in
the tubing, indicating that 70% of the free gas is entering the pump, which
corresponds to the 30% free gas separation that was specified. The pump
discharge is at a pressure of 8127 kPa, and at this elevated pressure all of the
gas passing through the pump has been forced back into solution, hence the
0% free gas value at this location. Note that the solution GOR at the
discharge is 14.7 m3/m3. The gas volume comprising the difference between
the 20 m3/m3 producing GOR and the solution GOR at the discharge has been
separated up the casing. The 5.3 m3/m3 difference when multiplied by the
surface oil rate of 60 m3/D equates to the surface casing gas rate of
318 m3/D. At the low pressure locations in the tubing (i.e. tubing head

pressure), the fluid rates increase significantly due to the breakout and
subsequent expansion of free gas.
The multiphase flow behavior can be viewed graphically within the Multiphase
Flow tab as shown below.

Using the Chart drop-down list, you can switch between five different charts.
The "In-Situ Flow Rates" chart shows the oil, water and free gas rates along
the length of the tubing. With the existing conditions, the gas does not break
out of solution into a free gas phase until it is approximately 312 m from
surface. This is confirmed in the "Produced Gas" chart which shows the free
gas to be 0% below this location. Also displayed on the "Produced Gas" chart is
the solution GOR which is equal to the tubing GOR until gas begins to break
out of solution. The "Flow Pattern" chart illustrates the flow patterns that exist
along the tubing string. Note that the flow pattern changes from single-phase
liquid to bubble and then to slug as the fluid moves from the pump discharge
to surface. The "Liquid Holdup" chart displays the magnitude of the twophase
and noslip liquid holdup throughout the tubing.
You have established that with the existing configuration, gas interference is
causing low apparent volumetric efficiencies and the requirement for high
pump speeds. However, several other issues of interest still remain to be
examined. As a benchmark, note the power costs of $34.87 per day. The
pump pressure loading and maximum rod stress are both relatively low at
63.62% and 63.98%, respectively. Prime mover output power is 35.85 hp,
which exceeds the rated capacity of the existing 30 hp electric motor.
Next, you need to evaluate the effectiveness of adding a tail joint It needs to
be positioned with the intake below the perforations, so that the free gas will
travel up the casing/tubing annulus and the liquid will move down into the tail
joint intake. Begin by moving back to the Equipment Configuration window
and opening the Tubulars window to specify a tail joint select the 60.3 mm x
6.99 kg/m size and grade. Because tail joints are added downward from the
pump, you need to specify a length of 45 m to position the intake below the
perforations at a depth of 1010 m. The window should appear as shown
below.

Click the OK button to confirm your entry and return to the Equipment
Configuration window. Click the Calculate button to update the results. A review
of the results shows that the pump speed required with this new configuration

has declined to 271.93 RPM from the previous value of 542.62 RPM. The
reason for this change is apparent from an output message that indicates that
the apparent volumetric efficiency has increased from 37% to 74%. Switch to
the Key Locations tab to examine the new operating conditions in more detail.
With the tail joint intake below the perforations, the free gas at the
perforations is assumed to be diverted up the annulus as opposed to entering
the pump. This increase in gas flow up the annulus is confirmed by the casing
gas rate which has increased from 318 m3/D to 1060.1 m3/D. This represents
90% of the total gas production. The table shows that there is no free gas at
the tail joint intake. However, as fluid moves upward through the tail joint,
the pressure drop associated with the decreasing hydrostatic head and
pressure losses leads to 24.22% free gas at the pump intake. Nevertheless,
this represents a substantial reduction over the 61.93% free gas which occurs
in the existing configuration. Another important point is that with the tail
joint, the flow rates through the tubing at surface are much lower, since more
gas is diverted up the casing.
The effect of the tail joint can also be seen within the Multiphase Flow output
window shown below.

The "In-Situ Flow Rates" chart shows the flow rates through both the tubing
and tail joint. The free gas flow rate increases from zero at the tail joint
intake to approximately 26 m3/D at the pump intake. Within the tubing, the
lower gas volumes do not result in any free gas flow.
Based on the analysis results, the addition of a tail joint to the existing
configuration would divert more gas up the annulus and result in less free gas
at the pump intake. The net result would be a substantial reduction in pump
speed. This is also reflected in the power costs, which are shown to decrease
from $34.87 per day to $18.96 per day. Although the pump pressure loading
(70.66%) and rod stresses would increase slightly (69.09%), they would still
be well within acceptable limits. Additionally, the prime mover output power
would decline significantly from 35.85 hp to 19.49 hp resulting in the motor
overloading condition being eliminated.
A final option in this evaluation is to try and locate a pump which can be run
through the casing patch restriction. Begin by making a copy of the first case,
moving back to the Equipment Configuration window and opening the Pump
Selection window. Note that the 102 mm outside diameter of the existing
pump prevents it from being run through the 100 mm drift at the casing
patch. Try locating a pump that has an outside diameter below 100 mm. Keep

in mind that in order to produce the required fluid rate, its displacement must
be close to the 0.395 m3/D/RPM value of the existing Kudu Industries
200TP1200SL pump. One pump that meets these requirements is the Kudu
Industries 200TP1200SL (SH). It has an outside diameter of 94 mm and a
displacement of 0.395 m3/D/RPM. Add this model to your selected list and
return back to the Equipment Configuration window.
Next, change the pump seating depth to 1010 mKB so that the pump is located
below the perforations. Finally, go into the Tail Joint Selection window and
remove the tail joint. When you return to the Equipment Configuration
window, it should appear as shown below.

Although the specified tubing and rod strings no longer extend to surface,
PCPUMP will adjust for this automatically during the analysis. Click Calculate to
perform the analysis. The updated analysis Summary output window should
appear as shown below.

With this new configuration, the pump speed is shown as 206.67 RPM. This is
a substantial improvement over the existing speed of 543 RPM and the speed
of 272 RPM determined with the addition of a tail joint. This decrease in speed
can be attributed to two factors.
First, the new pump has a larger
displacement and thus can produce equivalent fluid rates at lower speeds.
Second, because the pump intake is now below the perforations, there is no
free gas present at the intake. You can confirm this condition by examining
the Key Locations and Multiphase Flow output windows.
Before accepting that this new configuration is the best option, it is important
to review the other key considerations. The power costs have been reduced to
$14.42 per day, which is around 40% of the costs for the existing
configuration. The prime mover output power of 14.82 hp is well below the
30 hp rating of the existing electric motor. Rod stresses are listed as 69.34%
of yield, which is well within the acceptable guidelines.
One other concern with this modified equipment configuration is the surface
equipment operation. Move to the Prime Mover tab in the Drive Equipment
window where the operating frequency is now 31 Hz. This is because the
surface equipment configuration was left unchanged, while the pump speed
was reduced dramatically. To correct this problem, return to the Equipment
Configuration window and increase the belt reduction ratio on the new
equipment case from 3:1 to 5:1. When you recalculate the results, the

electric motor operating frequency will now be at a more appropriate value of

52 Hz.
This sample session has illustrated how a multiphase flow assessment can be
used to troubleshoot a production problem and come up with an alternative
system design which may be more appropriate. When utilized correctly, this
mode of PCPUMP can be very powerful. However, more so than anywhere else
in the program, improper inputs (e.g. excessive producing GOR's) can lead to
erroneous results.
Take appropriate steps to validate your data before
performing this type of analysis.

You are here: Sample Sessions > Session 6: Backspin and Fatigue Analyses

Session 6: Fatigue and Backspin Analyses

Note: The samples in this Help File are based on PCPUMP v3.15. If you are
using a later version of the program, or an updated database, some of the
results you get may not be the same. Also, some of the equipment selected in
this Help File may no longer be available in the database. If this is the case,
select the closest match available.
This sample session demonstrates the use of PCPUMP's surface drive backspin
and rod fatigue analyses capabilities which are included as auxiliary analysis
modules within the program.
Rod string fatigue analyses should be
undertaken in any case where severe alternating loads may occur, including
rod-driven PC pump operations in highly deviated wells. The backspin module
is a valuable tool for assessing the capability of surface drive equipment and
braking systems to safely release the stored rod string or fluid column energy
during both normal shutdown and seized pump situations. It is assumed that
the user is already familiar with the PCPUMP features introduced in the
previous sample sessions.

A. Fatigue Analysis
Scenario:
The fatigue assessment will make use of the same wellbore geometry,
equipment configurations and operating conditions specified in Sample Session
#2.
That session focused on the design of a horizontal well and the
configuration of a PC pumping system to address well profile, rod string
loading and tubing wear considerations. For this session, the production
system will be exposed to operating load variations in addition to the
alternating bending loads inherent to rod strings rotating in curved wellbores.
As a result of the cyclic loading conditions, the fatigue life of the rod string
must be considered as a design issue.

Objective:
Examine the fatigue life of a rod string installed in a directional well and
operating under cyclic loading conditions.

Data:
Well Profile, Equipment Configuration, Fluid
Conditions: Identical to Sample Session #2

Properties

and

Operating

Fatigue Loading:
Rod Ultimate Strength: 776.3 MPa
Surface Finish Type: Hot Rolled
Alternating Torque Amplitude: 50 Nm
Alternating Axial Load Amplitude: 1000 N
Fluctuation Period: 60 seconds

Procedure:
In order to minimize data entry requirements, the first step of this assessment
is to load the data file SS_6A.pcp. This is done by clicking on the File menu,
selecting the "Open" command and locating the file in the PCPUMP directory. It
is recommended that this file be saved under a new name so that any changes
you make will not affect the original file. Alternatively, you may refer back to
Sample Session #2 and enter all of the system configuration and operating
data required to begin this session. Since the fatigue module completes
auxiliary calculations that are dependent on the results of the primary
analysis, you must execute the program before the fatigue assessment can be
undertaken.
Under the Case Manager area, select the equipment case entitled "Initial
Design" for the initial fatigue analysis and click the Calculate button to perform
the analysis. The fatigue calculation will incorporate the rod string
configuration and well geometry that has been specified, as well as the results
from the rod string loading analysis. Select the Rod String Fatigue tab in the
Auxiliary Analysis window.
Several inputs must be entered in the edit boxes within the window before the
fatigue analysis can be completed. Use the default value of 776.3 MPa for Rod
Ultimate Strength and choose "Hot Rolled" as the rod Surface Finish Type. The
remaining inputs describe the operational load fluctuations experienced by the
rod string. Variations in the fluid column loading due to gas or water slugging
within the tubing can cause significant changes in the pump discharge
pressure, resulting in torque and axial load variations.

Definition of Fatigue Loading Parameters

Since the size and frequency of these load variations are often difficult to
predict when designing a new well or PC pump system, the fatigue evaluation
has been designed in the form of a sensitivity analysis so you can quickly
assess a representative range of fatigue loading conditions. For now, select 50
Nm as the alternating Torque Amplitude, 1000 N as the alternating Axial Load
Amplitude, and 60 seconds for the Fluctuation Period. As noted above, the
bending component of the alternating loading is governed by the wellbore
geometry, rod string configuration and axial loading. When the rod string in a
deviated well is under tension, most of the curvature in the rods is
concentrated adjacent to the connection upsets due to increased stiffness of
these elements. While the use of larger diameter couplings, centralizers, or
rod guides serves to increase this curvature, the localized bending effect can
be mitigated by increasing the number of contact points between the rod string
and tubing (i.e. using multiple rod guides or continuous rod in areas of high
curvature). This approach should improve the rod string design for both
fatigue and wear considerations, but may it also cause an unacceptable
increase in flow losses in some cases.
As soon as any of the input fields are updated the results section of the
window is updated. The first tab in the results section shows the results for the
base case analysis as shown in the windowbelow. For the conditions specified,
the calculated minimum fatigue life is 252.5 days at a measured depth of 181
mKB. The maximum EDF (elastic design factor) and DDF (deformation design
factor) are well within acceptable design limits, with values of 0.632 and 0.493
respectively (refer to the Rod String Fatigue section of the Help File for more
information on the stress/strain analysis techniques used in PCPUMP).

The results of the alternating torque sensitivity analysis are shown below.

It is apparent that the minimum fatigue life in the rod string is greatly affected
by the magnitude of the alternating torque and the fluctuation period. Clearly,
the rod fatigue life is much more sensitive to the alternating torque than it is
to the alternating axial load in this case. The three chart tabs summarize the
results of the analysis, which are shown below. Note that the Measured Depth
vs Life chart shows the fatigue life along the entire rod string. The results for
the base case show the fatigue life is lower in regions of high dogleg severity
due to the rotating bending loads. The other two charts show the sensitivity of
the rod fatigue life to alternating axial loads and torque variations.

Fatigue Analysis Output Charts

Now re-run the main calculation with the equipment case called "Modified
Design". Run the fatigue analysis for this equipment configuration with the
same inputs used in the previous case. The results for the new base case
show the fatigue life is infinite along the majority of the rod string. The
sensitivity analysis also shows that a higher level of alternating torque is
necessary to cause a fatigue failure. These improvements in the predicted
fatigue life can be attributed to the more gradual curvature of the sucker rods
when numerous rod guides are used in regions of high dogleg severity. Note
that the rod guide optimization procedure was used in Sample Session #2 to
select the rod guide distribution for this application based on a prescribed limit
for the rod guide contact load.
As an additional exercise, perform the fatigue analysis with a string of 25.4
mm (1") grade DR continuous rod. You will find that the fatigue life is
improved further relative to the rod guide case. The sensitivity analysis
predicts infinite rod string fatigue life for the entire range of torques, axial
loads, and fluctuation periods considered. The improvement is due to the fact
that continuous rod eliminates the curvature concentration effects which occur
when using couplings, centralizers, and rod guides in deviated wellbores.

B. Backspin Analysis
Scenario:
A vertical well which has been on production for some time with a PC pumping
system has recently experienced a substantial increase in water cut. The
operator is aware that fluid conditions can impact the amount of energy that
must be dissipated when the surface drive system is shutdown, and would like
to complete an assessment of the backspin response under the new operating
conditions. The analysis will check whether the backspin speeds will be kept to
a safe limit by the currently installed surface drive and brake system under
both normal shut down and seized pump situations.
Note that brake system specifications are currently not available for most
drivehead units, and therefore assumed brake characteristics have been used
in this illustrative example. Contact your equipment supplier to obtain specific
and current brake information before completing backspin analyses. The

backspin module in PCPUMP has been designed to facilitate sensitivity analysis

with variations in key parameters, as well as analysis of the system response
with the brake disengaged as a worst case scenario. Results from a backspin
analyses can be used to assess drive system requirements or to predict the
backspin behavior of a PC pumping system corresponding to the brake
specifications provided by the manufacturer.
Warning: it is important to recognize that the predicted results provide no
guarantee against the occurrence of an uncontrolled backspin event or sheave
or motor failure.

Objective:
Determine whether the braking characteristics of the current surface drive
system are adequate to limit the backspin speeds and brake temperatures to
acceptable levels for the existing operating conditions under both seized pump
and normal shutdown situations. Also complete a sensitivity analysis to assess
the effects of variations in the fluid level and seized pump torque on the
backspin response.

Data:
Wellbore Geometry
Well Type: Vertical
System Configuration:
Pump Seating Depth: 1000 m
Mid-Perforation Depth: 990 m
Casing: 139.7 mm x 23.07 kg/m
Tubing: 73.0 mm x 9.70 kg/m
Rod String: 25.4 mm Grade D (7.62 m length) with API slimhole couplings
PC Pump: Kudu Industries 400TP1350
Pump Volumetric Efficiency: 75%
Surface Equipment:
Weatherford (BMW) M4 Drivehead
4:1 sheave reduction with 95% power transmission efficiency
60 hp 6 pole electric motor with 92% efficiency and power factor of
0.85, and a 60 Hz, 460 Volt power supply.

Fluid Properties:
Fluid Composition
Water Cut: 70%
Sand Cut: 0%
Gas Specific Gravity: 0.7
Fluid Density: 961 kg/m3 (tubing and casing)
Fluid Viscosity
Fluid Viscosity: 100 cp
Operating Conditions:
Pump Speed: 200 RPM
Fluid Level: 650 m
Tubing Head Pressure: 200 kPa
Casing Head Pressure: 200 kPa
Bottomhole Temperature: 50C
Temperature Gradient: 0 C /100 m
Backspin Characteristics:
Motor Rating: 60 hp
Motor Poles: 6
Driven Sheave Diameter: 635 mm
Driver Sheave Diameter: 159 mm
Gearbox Reduction: none (1:1)
Surface Equipment Friction: 20 Nm
Pump Friction Torque: 100 Nm
Pump Volumetric Efficiency: 75%
Fluid Density: 961 kg/m
Fluid Viscosity: 100 cp
Braking Location: Polish Rod
Brake Activation Speed: 0 RPM
Maximum Brake Temperature: 150C
Brake Specific Heat Capacity: 100 kJ/C

Procedure:

Begin with a new PCPUMP data file. In the Equipment Configuration window,
specify a Pump Seating Depth of 1000 mKB and a Mid-Perforations Measured
Depth of 990 mKB. The well is vertical so there is no need to specify a
wellbore geometry. Choose a Kudu Industries 400TP1350 pump with a Pump
Friction torque of 100 Nm and a Volumetric Efficiency of 75% (i.e. not the
default value). Next, specify 1050 m of 139.7 mm x 23.07 kg/m casing and
1000 m of 73.0 mm x 9.70 kg/m tubing. Also input a 25.4 mm High Strength
sucker rod string (131 rods) with 7.62 m length rods and API slimhole
couplings.
Now move to the Surface Drive Equipment Selection window and check the
Surface drive equipment active box at the top of the screen. Select a Weatherford
(BMW) M4 drivehead.
Also activate the belts option and assign a 4:1
Reduction Ratio and Power Transmission Efficiency of 95%. Next, specify a 60
hp electric motor with 6 poles, a Motor Efficiency of 92%, and a Motor Power
Factor of 0.85. Assume the Supply Frequency is 60 Hz and the Supply Voltage
is 460 V, and indicate that the pump speed should be matched by adjusting the
prime mover speed. Once you have verified the data entries, close the
window.
Move to the Fluid Properties window and enter a Water Cut of 70%, casing and
tubing fluid densities of 961 kg/m, Gas Specific Gravity of 0.7 and a Fluid
Viscosity of 100 cp. Next, move to the Operating Conditions window and
specify a Pump Speed of 200 RPM, Fluid Level of 650 mKB, tubing and casing
head pressures of 200 kPa, Bottomhole Temperature of 50C, and no
temperature gradient. Note that the fluid rate and bottomhole pressure are
calculated variables. Click Calculate to run the system analysis. The analysis
results Summary tab is shown below.

Enter the backspin module by selecting the Auxiliary Analysis window and click
on the Backspin tab. Start by entering the required values in the Specification
area. Input a driver sheave Diameter of 159 mm and a driven sheave
Diameter of 635 mm.
Note that these dimensions match the 4:1 belt
reduction specified previously for the surface equipment. Enter a value of
20 Nm for Surface Equipment Friction. The remaining equipment and fluid
property inputs can be automatically updated to the corresponding inputs
specified previously by clicking on the Load Specifications button. These
inputs can also be changed manually if you want to run a simulation with
different values. Next, click the Load Inertia Defaults button. This assigns default
mass moment of inertia values to the motor, sheave, and gearbox components.
If it is not convenient to obtain these specifications from the equipment
manufacturers, the calculated defaults should, in general, serve as reasonable

estimates of the actual inertia values.

Brake characteristics are input in a separate window that can be accessed
using the Specify button next to Brake Specifications. To minimize the input
requirements, a brake file has already been created for use in this sample
session. The file name is "sampsession #6 brake file". Choose the brake model
called "sample". The brake specifications should now be visible. Note that the
torque response of the specified brake varies linearly with speed and
temperature changes, as does the energy dissipation rate with differential
temperature. Clicking on the Charts tab displays the torque response and
energy dissipation characteristics of the brake in chart format. The Braking
Location drop-down list shows that the brake currently acts at the polish rod.
You will also notice that the Brake Activation Speed is 0 RPM (i.e. resistive
forces are activated as soon as the system begins to move backwards) and that
the Maximum Brake Temperature is 150C. The Custom Equipment window
should appear as below.

Click OK to close the Custom Equipment window. Select Seized Pump next to
Scenario at the top of the window. Several additional inputs are required
before the analysis can begin. Choose 25C for the initial brake and ambient
temperatures. Assign a value of 1442 Nm to the Seized Pump Torque, since
the lesser of the two calculated torque limits will generally govern the
response. This value represents the theoretical maximum torque that the rods
could sustain before breaking.
When you have finished entering the input data, the window should appear as
shown below.

The seized pump analysis can then be executed by clicking on the Calculate
button on the left-side of the screen. After a brief calculation period, results
should appear in the Backspin Results window. The results presented include
the peak rotational speeds of the various surface equipment components.
Note the difference in peak speed between the electric motor (5634 RPM) and
the rod string (1411 RPM) due to the 4:1 sheave reduction. Of particular
interest are the peak rim velocities of the sheaves. A typical recommended
peak rim velocity for standard cast iron spoked sheaves is 33 m/s
(6500 ft/min.). In this case the peak velocity is 46.9 m/s, well above the
recommended maximum. Also shown on the output screen are the peak and
final brake temperatures, the torque retained in the rod string at the end of
the backspin period, and the total amount of energy dissipated by the brake

and by the overall system during the backspin event.

The backspin response can be viewed in two different chart displays. The
Backspin Response chart shows the polish rod speed, rod torque, and system
energy as a function of time for the entire backspin period. The Braking
Response chart shows the applied brake torque, polish rod speed, and brake
temperature responses, also as a function of time.

Seized Pump Analysis Output Charts

Close the results window and check the Calculate Sensitivity box to perform a
sensitivity analysis for the seized pump case. This will run the backspin
analysis for a range of seized pump torque values. The results of this analysis
are presented in two additional charts which show the backspin time, brake
temperatures, and peak speeds as a function of the initial seized pump
torque. These charts should appear as shown below.

Seized Pump Sensitivity Output Charts

Based on the calculated peak backspin speeds, the brake system appears to be
adequately sized for the seized pump backspin scenario.
There are two additional options listed that are available for the seized pump
case. One or both of these options, Broken Belts and Brake Disengaged, can
be selected to determine their effects on the system response. To experiment,
disable the brake by choosing the Brake Disengaged (No Braking Action) option and
repeat the backspin analysis. Note the increase in sheave rim velocity.
Choosing the Broken Belts option removes the effect of the motor and driver
sheave inertias from the analysis, as would be the case if the belts actually
broke. Note that the seized pump analysis is slightly conservative in ignoring
the effects of fluid viscosity on the resistive rod torque.
Now change the analysis Scenario to Normal Shutdown at the top of the window.
Specify the operating Pump Speed of 200 RPM and the Fluid Level of 650 mKB
in the appropriate input boxes. Click the Calculate button to commence the
analyses. The normal shutdown calculations typically take much longer to
complete than the seized pump calculations due to the large difference in the

energy stored in the system. When the calculation is complete, the Backspin
Results window is updated. In addition to the values displayed previously for
the seized pump case, the results include the total number of backspin
revolutions, the total volume of fluid that has drained from the tubing, and the
final fluid levels in the tubing and casing. Note the large amount of torque
retained in the rod string at the end of the backspin period due to a
combination of surface and pump friction. This shows why extreme caution
must be exercised in the field whenever a polish rod clamp is removed, as the
retained torque will likely be released immediately upon the disconnection of
the polish rod from the surface drive.
Now examine the additional output charts available for the normal shutdown
backspin analysis. The chart entitled Fluid Level Response shows the change
in the casing and tubing fluid levels and the resulting variation in hydraulic
torque throughout the backspin sequence.

Normal Shutdown Fluid Levels Output Chart

Sensitivity analyses may also be conducted for the normal shutdown backspin
scenario by selecting the Calculate Sensitivity option. This option completes
several simulations with varying initial casing fluid levels. The results of the
analysis are presented in charts as shown below.

Normal Shutdown Sensitivity Output Charts

Five calculation options are available for the normal shutdown scenario. In
addition to the two options available for the seized pump analysis, you can
also specify a perforation pressure threshold above which the fluid draining
from the tubing will flow back into the reservoir as opposed to the
casing/tubing annulus. Try completing another analysis with a value of 3500
kPa specified for this parameter. Note the discontinuity in the speed and
torque curves at the point of flowback. This can be attributed to a substantial
reduction in flow losses within the annulus when the fluid begins to flow back
into the reservoir. Try running the simulation again with both the Ignore Flow
Considerations During Backspin and reservoir flowback options checked. Because
flow losses in the casing have been disregarded, the discontinuity is no longer
visible. The fifth option, Ignore Rod/Tubing Friction During Backspin, controls whether
the frictional loading associated with contact between the rod string and tubing
is considered in the analyses. This option is useful for analyzing highly

deviated wells where the rod/tubing contact may produce a significant amount
of resistive torque.
In summary, the predicted backspin response shows that the selected brake
system is adequate for both the seized pump and normal shutdown cases. The
peak speeds of the sheaves were well below their recommended limits in the
seized pump case. The results for the normal shutdown case show that both
the peak speeds and peak temperatures are also well within acceptable limits.

You are here: Sample Sessions > Session 7: Basic Downhole Drive

Session 7: Basic Downhole Drive

Note: The samples in this Help File are based on PCPUMP v3.4. If you are
using a later version of the program, or an updated database, some of the
results you get may not be the same. Also, some of the equipment selected in
this Help File may no longer be available in the database. If this is the case,
select the closest match available.
This sample session introduces the basic features of PCPUMP's downhole drive
analysis capabilities.

Scenario:
A surface drive system running a PCP in a deviated well is experiencing severe
rod/tubing wear problems. The operator is interested in using a downhole
drive system in an effort to overcome these problems.
The existing surface drive system is coupled to a R&M Energy Systems (Moyno
Brand 14-T-40 (ML)) pump and is producing 120 m/D of fluid to surface. The
fluid has a water cut of 30%, sand cut of 2%, and the fluid viscosity is 40 cp.
The pump is seated at 1150 mKB, 50 mKB above the mid-perforation depth.
The existing pump is to be re-used in the new system, which should be
designed to maintain the existing production rate. A VFD is available for speed
control on the new downhole drive system.

Objective:
Design a downhole drive PCP system to replace the existing surface drive
system for the high-volume deviated well. Model the system using singlephase fluid properties. Re-use the existing pump and tubing.

Data:
Wellbore Geometry
Well Type: Deviated (mid-perforations at 1200 mKB)
Proposed Surface Drive Configuration:
Casing: 177.8 mm x 34.23 kg/m (drift diameter 158.5 mm)
Tubing: 88.9 mm x 13.8 kg/m
Rod String: 25.4 mm Grade D standard rods with slimhole couplings (7.62

m length)
PC Pump: R&M Energy Systems (Moyno Brand 14-T-40 (ML)) seated at
1150 mKB
- displacement = 0.395 m3/D/RPM
- pressure rating = 13152 kPa
- pump friction = 100 Nm
- volumetric efficiency = 92%
Proposed Downhole Drive Configuration:
Tubing: existing 88.9 mm x 13.8 kg/m
PC Pump: existing R&M Energy Systems (Moyno Brand 14-T-40 (ML))
Downhole Motor: to be determined
Drive Assembly: to be determined
Power Transmission Cable: to be determined
Fluid Properties:
Fluid Composition
Water Cut: 30% (based on existing well)
Sand Cut: 2%
Gas Specific Gravity: 0.7
Oil API Gravity: 18API
Water Specific Gravity: 1.03
Sand Specific Gravity: 2.65
Tubing Density Factor: 1.0
Casing Density Factor: 1.0
Fluid Viscosity
Fluid Viscosity: 40 cp
Operating Conditions:
Fluid Rate: 120 m3/D
Fluid Level: 900 mKB
Tubing Head Pressure: 750 kPa
Casing Head Pressure: 750 kPa
Bottomhole Temperature: 37C
Temperature Gradient: 2.5C/100 m

Procedure
In this session, you will evaluate:
the existing surface drive configuration;
an alternative downhole drive configuration.
Begin by starting PCPUMP and specifying the surface drive system
configuration. Since these systems are installed in a deviated well, the first
step in the analysis must be to specify a wellbore geometry. Move to the
Wellbore Geometry window to enter the wellbore geometry module. The
directional survey for this well has been created and saved in the Samps7.wbr
file. Import this file using the Import button. The wellbore consists of a short
vertical section followed by a gradual increase in inclination to a final hole
angle of 44 at a total measured depth of 1217 mKB. After you have imported
the wellbore, return to the Equipment Configuration window and specify the
Mid-Perforations Measured Depth of 1200 mKB.
For the existing surface drive system, the pump is seated at a measured depth
of 1150 mKB. Move to the Pump Selection window and choose the R&M
Energy Systems (Moyno Brand 14-T-40 (ML)) pump. Assign a Pump Friction
torque of 100 Nm and Volumetric Efficiency of 92% to this pump. Continue by
selecting 1217 m of 177.8 mm x 34.23 kg/m casing and 1150 m of 88.9 mm x
13.8 kg/m tubing. Select a full string of 25.4 mm Grade D sucker rods (7.62
m length) with slimhole couplings. Do not select any surface drive equipment
for this system.
After completing the equipment configuration, move to the Fluid Properties
window. Select the Calculate Fluid Density option for single-phase fluid properties.
Specify an Oil API Gravity of 18, Water Cut of 30%, and Sand Cut of 2%.
Use values of 1.03 for the Water Specific Gravity, 2.65 for the Sand Specific
Gravity, and 0.7 for the Gas Specific Gravity. Leave the casing and tubing
density factors unchanged at values of 1.0. Finally, specify the Fluid Viscosity
of 40 cp.
Next, move to the Operating Conditions window. Define a Fluid Flow Rate of
120 m/D and Fluid Level of 900 mKB. Enter a value of 750 kPa for the tubing
and casing head pressures, and specify a Bottomhole Temperature of 37C and
wellbore Temperature Gradient of 2.5 C/100m.
Now that the input information has been entered, click the Calculate button to
initiate the analysis. The analysis Summary tab should appear as shown
below.

The analysis results summary shows that the pump speed resulting from the
120 m/D fluid rate is 330 RPM and that the pump pressure loading is
61.55%. An output message indicates that flow losses account for 2.85% of
the pump differential pressure. A quick examination of rod/tubing contact
loads indicates that the maximum coupling/tubing contact load is 313.67 N,
which is high enough to have caused the wear problems with the system.
(Refer to the Rod/Tubing Contact tab for more details.)
For the purposes of designing an equivalent downhole drive system it is helpful
to examine the amount of power required to drive this surface configuration.
Open the Energy Flow tab of the Analysis Results window. The window should
appear as shown below.

Power and efficiency values are not displayed for surface drive components
because they were not included in the analysis. However, the amount of
power required to rotate the rod string from surface is shown as 25.63 hp in
the upper table in the "Power Input" column of the "Rod String (Rod/Tubing
Friction)" row. Notice that approximately 20% of the power in the system is
used to overcome the mechanical friction caused by the contact between the
rod string and tubing.
After you have examined the results of the surface-drive analysis, move back
to the Equipment Configuration window. Our goal is to design a downhole
drive system that will operate under the same conditions and produce the
same amount of fluid as the existing surface drive system. Note that you can
easily switch between Surface and Downhole drive system specifications by
clicking under the Drive Location area in the upper-left corner of the window.
Under the Case Manager area, make a copy of your existing case. Rename this
case by right-clicking on the name of the new case, selecting "Rename Case"
and typing "New Downhole Drive System". Also rename the original surface
drive case to "Old Surface Drive System". Ensure that the new downhole drive
case is selected and select the downhole drive location in the Equipment
Configuration window.

Notice that the pump, casing, and tubing, wellbore geometry, and pertinent
depths are defined as they were previously. The database viewer indicates
that the drift diameter of 177.8 x 34.23 kg/m casing is 158.5 mm. This value
will be important when considering clearances for installing power

transmission cable.
To finalize the downhole drive equipment configuration, the drive equipment
must be selected. Enter the Downhole Drive Equipment Selection window
where three components must be specified: drive assembly, motor, and power
transmission cable. The drive assembly is treated in a generic fashion and
includes all the equipment that connects the downhole motor to the PC pump.
Drive assemblies may consist of gear reduction equipment, seals, thrust
bearings, and devices used to absorb the eccentric motion of the pump rotor.
Begin by selecting Centrilift as the manufacturer Company of the drive
assembly from the list of available manufacturers under the Drive Assembly
tab. Now select an assembly Model. The 5259 model has an outside diameter
of 133.35 mm, a horsepower capacity of 65.58 hp, and a gear reduction of
9:1. The diameter of the unit should be adequately small to ensure a smooth
installation in the selected casing. The horsepower requirement on the
assembly is likely to be less than 60 hp given the power required by the
surface drive system was 25.63 hp. With the knowledge that the pump in use
will be running at 330 RPM and that the Centrilift motors currently available in
the database are 2-pole motors (i.e. synchronous speed of 3600 RPM), this
gear reduction should allow for a motor operating frequency in the range of
50-60 Hz. After selecting this model you will notice that other pertinent
equipment characteristics are displayed on the selection window.
Next, move to the Motor tab. Once again, choose Centrilift as the equipment
manufacturer. Select the GMF 30 hp, 795 V motor. The 30 hp output power
rating should be adequate to handle the power requirements of the pump and
drive assembly, and the 138.2 mm outside diameter will likely fit into the
casing without any difficulty. Other pertinent operational limits are displayed
on the window. You must still specify a number of motor performance
parameters:
efficiency, power factor, motor slip, and motor winding
temperature rise. As described in the PCPUMP User's Guide, there are three
ways to specify these values. You may specify values that remain the same
regardless of the motor's loading or frequency, use performance curves data
provided by the motor manufacturer (not always available), or use the results
of motor testing to model the performance of the motor. In this sample
session, static values will be specified; select that option by selecting No curves
(static) under the Curves tab on the right-side of the window.
Specify an
Efficiency of 75%, Power Factor of 0.70, motor Slip of 100 RPM, and winding
Temperature Rise of 15C. The Motor tab should appear as shown below.

The final downhole drive component to be selected is the power transmission

cable.
Move to the Cable tab.
Select the Centrilift CEEF
(EPDM/EPDM/Tap/Braid)#1 5KV model. This flat cable has a thickness of
about 19 mm. Cable ampacity curves are shown on the right-side of the
window. You may toggle between "Cable Losses at Conductor Temperature"
and "Conductor Temperature at Ambient Temperature" charts using the Chart
drop-down list. Close the Downhole Drive Equipment Selection window by
clicking OK.
It is critical to make sure that the motor and drive assembly are located above
the perforations for motor heating considerations. PCPUMP does not permit
users to conduct analyses with the motor located below the mid-perforation
depth unless a shroud is specified.
A quick examination of the tubing
summary table on the Equipment Configuration window for the selected system
shows that the bottom of the motor is located at 1143.1 mKB. In this
particular case, the mid-perforation depth is at 1200 mKB.
No changes to the previously specified fluid properties and operating
conditions are necessary to conduct the downhole drive analysis. Additional
fluid properties may be specified so a motor heating analysis may be
conducted if desired. For now, let us assume that motor heating effects are
not a significant operational issue. Click the Calculate button to initiate the
downhole drive analysis. The analysis Summary tab should appear as shown
below.

As in the surface drive case, the pump speed corresponding to the 120 m/D
fluid rate requirement is 330 RPM, although the pump pressure loading
decreased slightly to 60.39% (the decrease is due to reduced pressure losses,
because the rod string was removed). The corresponding motor operating
frequency is 51.20 Hz. A check shows that flow losses now represent 0.99% of
the total pump differential pressure. Note that the downhole motor output
power for this analysis case is 25.22 hp.
Examining the Energy Flow window provides a more detailed breakdown of the
amount of power required by each component of the system. The power
transmission cable contributes little to the power loss as it is operating at an
efficiency of 96.25%. The primary power losses in the system occur in the
electric motor (efficiency of 75%), drive assembly (efficiency of 82.15%) and
the pump (mechanical efficiency of 77.61%), which combine to lower the
overall system mechanical efficiency to 46.03%.
The Drive Equipment tab provides further details on the performance of each
of the components of the downhole drive system. A quick examination shows

that the drive assembly is adequately sized for thrust, torque, power and
speed considerations. The downhole motor is operating at 98.5% power
loading. Because the motor operating frequency was adjusted to 51.2 Hz, the
motor operating voltage and power rating were adjusted accordingly. The fluid
velocity past the motor (considered an important parameter for heat transfer
considerations) is 0.251 m/s, which is less then the recommended minimum of
0.3 m/s. A quick hand calculation indicates that the Reynolds number of the
flow is only 140, which increases the concerns related to motor heating.
To perform a more detailed motor heating analysis, go back to the analysis
Options window by clicking the appropriate tab at the top of the window. Click
on the check-box under the Motor Heating Analysis area. You must specify fluid
thermal properties for this analysis; do this by going to the Fluid Thermal
Properties tab under the Fluid Properties window. You may allow PCPUMP to
calculate representative values by selecting Derived From Fluid Composition and Use
Default Values. Click on Calculate to recalculate the results. Most of the displayed
results are unchanged, except for the motor winding temperature, which is
now 212.9C. An output message was also issued suggesting you contact the
motor manufacturer for temperature information. For this specific motor, there
is no temperature rating provided by the manufacturer in the PCPUMP
database. The estimated operating temperature, however, is quite high and the
motor may be subject to a short run life if allowed to operate in these
conditions.
An examination of the Key Locations table shows that the produced fluid
temperature increased by 1.7C when flowing past the motor. For fluids with
temperature-sensitive viscosity (as would be defined using PCPUMP's advanced
viscosity features), this temperature increase may have a considerable impact
on pressure losses. In this sample session, however, we are assuming that the
fluid viscosity is constant.
This sample session provided an introduction to the procedure for analyzing a
downhole drive PCP system. While downhole drive systems consist of different
components than conventional surface drive systems, the procedures followed
in system analysis using PCPUMP are virtually the same.

You are here: Sample Sessions > Session 8: Advanced Downhole Drive

Session 8: Advanced Downhole Drive

Note: The samples in this Help File are based on PCPUMP v3.4. If you are
using a later version of the program, or an updated database, some of the
results you get may not be the same. Also, some of the equipment selected in
this Help File may no longer be available in the database. If this is the case,
select the closest match available.
This sample session will illustrate some of the more advanced features of
PCPUMP's downhole drive analysis capabilities. The session also introduces the
advanced viscosity feature for multiphase flow.

Scenario:
A new vertical well is being completed to produce 15 API oil with a moderate
GOR. You are to design a downhole drive system for this well. You have the
results of dead oil viscosity testing at a range of temperatures to help you
model the fluid behavior. Sand problems are not expected in the well.

Objective:
Design a new downhole drive system for optimum performance. The target
flow rate is 200 m/D. The pump speed should be limited to 400 RPM to
prevent premature stator elastomer deterioration. The design evaluation
should consider the possible use of measures to handle free gas downhole,
such as lowering the pump below the perforations and adding a shroud. Motor
performance and heating must be investigated in detail.

Data:
Wellbore Geometry
Well Type: Vertical (mid-perforations at 940 mKB)
System Configuration:
Casing: 244.5 mm x 53.57 kg/m (drift diameter: 222.6 mm)
Tubing: 88.9 mm x 13.8 kg/m.
PC Pump: To be determined
Drive Equipment: To be determined

Fluid Properties:
Multi-Phase Fluid
Oil API Gravity: 15API
Water Salinity: 10,000 ppm
BS&W Content: 3%
Gas Specific Gravity: 0.7
Producing GOR: 40 m3/m3
Free Gas Separation: 65%
Fluid Viscosity
Note: dead oil viscosity/temperature relationship available
Operating Conditions:
Target Fluid Rate: 200 m3/D
Tubing Head Pressure: 1400 kPa
Casing Head Pressure: 1400 kPa
Bottomhole Temperature: 38C
Temperature Gradient: 2C/100 m
Vogel IPR:
Reservoir Pressure 10400 kPa
Bubble Point Pressure 7200 kPa
Test Point Pressure 4800 kPa
Test Point Flow Rate 160 m/D

Procedure
In this session, you will:
configure a downhole drive system;
conduct an analysis to determine an appropriate PC pump; and
examine the effects of adding a motor shroud.
Start PCPUMP and move the program to its downhole drive analysis mode in
the Equipment Configuration window by selecting the appropriate Drive
Location radio button. Since this well is vertical, you do not need to specify a
wellbore geometry. Specify a Pump Seating Measured Depth of 910 mKB and
input the Mid-Perforations Measured Depth of 940 mKB.

In selecting a pump, it is important to consider the speed at which the

downhole drive system will be operating. A decision has been made to use a
REDA 4-pole motor and drive assembly with 4:1 gear reduction for this
system. The synchronous speed of a 4 pole motor operating with 60 Hz power
is 1800 RPM. With a 4:1 gear reduction, one can therefore expect the output
shaft of the drive assembly to be rotating at a speed of 450 RPM when the
motor operates at synchronous speed. Knowing that the target fluid rate is
200 m/D, your choice of pumps should be made carefully. For now, choose
two different Dresser Monoflo pumps: D054/120 (0.541 m/D/RPM), and
D064/135 (0.636 m/D/RPM). Assign a Pump Friction torque of 100 Nm and
Volumetric Efficiency of 90% to each pump. One of these pumps will be
selected for the final system design.
Next, select a string of 244.5 mm x 53.57 kg/m casing 980 m in length. Note
that the drift diameter of this casing is 222.6 mm, and the nominal inside
diameter is 226.6 mm. Create a 910 m long string of 88.9 mm x 13.8 kg/m
non-upset tubing with corresponding connections. Given that these couplings
have a maximum outside diameter of 108 mm, you will need to override the
default coupling OD of 114.3 mm that appears when the tubing size is
selected. To do this, simply type the new coupling OD over the default value in
the appropriate box on the selection window and click the OK button.
To complete the equipment configuration, enter the Downhole Drive Equipment
Selection window. Because you have yet to conduct an analysis for this well,
modifications to the initial drive equipment configuration may be required.
Start by selecting a drive assembly; Company: REDA, Model: REDAPC 5.25
(4:1). This drive assembly has a 4:1 gear reduction. Other pertinent
attributes are listed on the selection window, including the outside diameter
(133.35 mm), power rating (70 hp), and maximum speed (545 RPM).
Move on to the Motor tab and select the REDA 540 Series, PK-UT
(70 hp, 1535 V) motor model. Relationships that can be used to model motor
performance are supplied by equipment manufacturers for the majority of the
motors in the PCPUMP database, (although you may not be able to view the
performance curves for the motors of some manufacturers). To activate the
manufacturer-supplied motor performance curves for this motor, select the Use
data from manufacturer option under the Curves tab on the right-side of the
window. Note that if motor performance curves are not available from the
manufacturer, this option will not be available; performance may still be
modeled using user-specified static performance values or motor test data.
Under the Charts tab, you can view the motor performance curves in a
graphical format. (Note that you will not be able to view the temperature
curve for this motor, although PCPUMP will perform a temperature calculation.)

Finally, move to the Cable tab and choose the REDA 1/7 ELB G4F (REDALEAD)
cable. This cable is flat and should easily fit into the wellbore along with the
tubing, drive assembly, and motor.
After closing the Downhole Drive
Equipment Selection window, the Equipment Configuration window should
appear as shown below.

Move to the Fluid Properties tab and select Multi-Phase fluid type radio button.
Set the Oil API Gravity to 15, Water Salinity to 10,000 ppm, Gas Specific
Gravity to 0.7, BS&W Content to 3%, and Producing GOR to 40 m/m. Select
Specify Free Gas Separation and enter the Free Gas Separation (intake* above
perfs) as 65%.
Viscosity values for multiphase fluids in PCPUMP are obtained in one of two
ways. By default, PCPUMP uses the Ng and Egobah correlation to relate the
oil's API gravity to a dead oil viscosity, and the Beggs and Robinson correlation
to find the live oil viscosity. If dead oil viscosity data is available for the well
fluid, the user can select the Use Advanced Viscosity option to specify the
relationship between dead oil viscosity and temperature. The Beggs and
Robinson correlation then makes the adjustment to live oil conditions at each
point in the wellbore. Check the Specify Temperature Effects box and enter the
following dead oil viscosity-temperature data into the table.
Temperature
(C)

Dead Oil Viscosity (cp)

20

1200

30

600

40

300

The Advanced Fluid Viscosity window should appear as shown below.

Next, specify the system's operating conditions by going to that tab. Start by
specifying a Fluid Flow Rate of 200 m/D, Tubing Head Pressure of 1400 kPa,
Casing Head Pressure of 1400 kPa, Bottomhole Temperature of 38C, and

Temperature Gradient of 2C/100 m. Also check the

click on the Specify button to open the IPR window.

Specify IPR data

box and

The IPR data available for this well will allow more accurate modeling of the
system loading to variations in fluid flow rate. Select the Vogel straight point
IPR correlation and enter the Static Reservoir Pressure of 10,400 kPa, Bubble
Point Pressure of 7200 kPa, test Producing Pressure of 4800 kPa, and
corresponding test Fluid Flow Rate of 160 m/D. The IPR relationship is
automatically plotted in the graph on the right-side of the window. Click OK to
close the IPR window to return to the Operating Conditions window.
Under the Options tab, click on the check-box under the Motor Heating
Analysis area. The motor heating analysis will calculate the motor winding
temperature and the increase in temperature of the fluid as it flows past the
motor. Since the oil viscosity is quite sensitive to temperature, this may have a
significant impact on the calculated results. In order for PCPUMP to complete
the motor heating analysis, the thermal properties of the fluid must be
defined. Go to the Fluid Thermal Properties tab of the Fluid Properties window.
The properties that must be defined are the fluid specific heat capacity (Cp)
and fluid thermal conductivity (K). The values for the fluid Cp and K can
either be specified by the user directly or can be derived from the thermal
properties of the various components of the fluid. Select Derived from Fluid
Composition to instruct PCPUMP to obtain these values from the properties of the
components of the fluid, and choose Use Default Values. Note that the gas specific
heat is set in the Defaults tab of the Preferences window. The gas thermal
conductivity is not required as it will not affect the results of the thermal
calculations.
For the first analysis of this system, make sure that the Dresser Monoflo
(D054/120) pump is active. The active pump may be selected from the list in
the Case Manager area at the top right-side of the main window. Click Calculate
to initiate the analysis. The analysis results Summary window should appear
as shown below.

From an examination of the Output Messages, it is apparent that there are a

number of refinements that must be made to the downhole drive system.
There is 33% free gas at the intake of the pump that is lowering the apparent
volumetric efficiency of the pump to 58%. Because of this, the system must
operate at 638 RPM to produce the 200 m/D target fluid flow rate. This
corresponds to a motor operating frequency of 87.2 Hz. Other results that are
displayed in the window include an acceptable pump pressure loading of
59.09% and a motor output power of 48.29 hp. This output power should

decrease if the gas separation efficiency is improved. Note that the final
choice of pump will not be made before major system reconfiguration options
are explored.
A quick examination of the results displayed in the Drive Equipment output
window should give us an indication of whether or not the selected equipment
is sized adequately. The selected drive assembly is operating within its limits
with the exception of its peak speed, which is at 117% of the recommended
maximum. The motor appears to be loaded at an acceptable level of 47.5%.
However, this level has been scaled with operating frequency and can be
expected to change when the speed of the pump is reduced to an acceptable
level. The velocity past the motor is 0.220 m/s, below the recommended
minimum of 0.3 m/s. As a consequence of insufficient motor cooling, the motor
winding temperature is 637.5C, well above the manufacturer's recommended
maximum temperature of 204.4C. (Note that in some cases, particularly with
viscous fluids, the cooling may still be insufficient if the velocity is above the
0.3 m/s recommended minimum. PCPUMP can help you determine if this is the
case.) The voltage loss in the power transmission cable is 0.0186 V/m, well
below the maximum recommended loss of 0.10 V/m.
Move back to the Equipment Configuration window. One solution to the gas
problem encountered in the initial analysis is to lower the intake of the system
below the perforations using a shroud to redirect the flow past the motor to
maintain acceptable cooling. This will encourage free gas at the perforations
to move up the casing as opposed to going through the pump. The shroud
configuration may also improve motor cooling, by increasing the flow velocity
past the motor, and bring the motor temperature to an acceptable level. Sand
should not pose a problem for the shrouded system in this case as negligible
sand cuts are expected.
Start by creating a copy of the current equipment case. Rename the initial
equipment case "No Shroud" and the new case "Shroud". Make sure that the
"Shroud" case is selected before making any changes to the configuration.
This new case should contain the same system configuration that was entered
previously.
The first change to the new configuration should be to lower the fluid intake so
that it sits below the perforations. The fluid intake in the new case will be at
the bottom of the motor (i.e. intake of the shroud). Move the pump intake to
a depth of 960 mKB. An examination of the summary tubing table in the
Equipment Configuration window shows that the bottom of the motor will now
sit below the perforations at a measured depth of 974.2 m. Enter the Tubulars
window and check the Shroud Active box. Specify a shroud Outer Diameter of
178 mm and an Inner Diameter of 164 mm. The shroud must provide an

internal clearance for fluid to flow past the motor and drive assembly and
external clearance for fluid to flow downwards from the perforations. The
shroud dimensions must also allow it to move easily through the casing drift
for installation purposes. The Tubulars window should now appear as shown
below. Click OK to accept the new equipment and return to the Equipment
Configuration window.

Click Calculate to initiate the analysis with the new equipment case.
analysis results Summary window will appear as shown below.

The

The pump speed displayed is 423.58 RPM, which corresponds to a motor

operating frequency of 58.91 Hz at this level of motor loading. An output
message indicates that the apparent volumetric efficiency is 87%. Changes
made to the system configuration appear to have alleviated the problem
caused by free gas at the intake in the first system configuration. Flow velocity
past the motor is now 0.385 m/s, and the motor winding temperature is
140.9C, below the motor's temperature rating. The pump speed shown,
however, is above the maximum of 400 RPM defined earlier in this sample
session.
Prior to finalizing the choice of downhole drive equipment, a
comparison should be made to determine which of the two available pumps is
most appropriate for use in this situation.
To view the pump comparison, click on the Show Analysis
The comparison table should appear as shown below.

Comparison Table

button.

The pump speeds displayed in the table show that the D064/135 will operate
at 360 RPM, below the established limit of 400 RPM at the 200 m/D target
flow rate. This speed corresponds to a motor operating frequency of 50.75
Hz. Close the Analysis Comparison window and highlight the D064/135 case.
The analysis Summary window should appear as shown below.

Other summary parameters of particular interest include the bottomhole

pressure of 2454.1 kPa, pump intake pressure of 2703.83 kPa, total flow loss
of 1079.91 kPa (12.73% of the total pump differential pressure), pump
pressure loading of 63.05%, motor output power of 36.60 hp, and system
mechanical/electrical efficiency of 62.77%.

Because of the high oil viscosity, the pressure drop through the small gap
between the downhole motor and drive assembly and the shroud is of
concern. Open the Key Locations window to examine pressures throughout
the system in more detail. The pressure at the motor bottom is 2767 kPa,
while the pressure at the pump intake is 2704 kPa. This corresponds to a 63
kPa pressure drop, in a 14.2 m long shroud, which is acceptable. The pump
intake pressure is still higher than the bottomhole pressure at the perforations
(2454 kPa) and therefore no additional gas came out of solution within the
shroud.
Note the temperature increase of the produced fluid past the motor, from
38.7C to 40.3C, and the corresponding decrease in fluid viscosity. There is
still a strong variation in fluid viscosity along the wellbore because the fluid
cools down as it flows up to surface. Open the Basic Fluid Flow output window
and select the "Temperature and Viscosity Profiles" chart to view the
temperature and viscosity as a function of well depth.
The Energy Flow window breaks down the system power requirement into
components and shows the efficiencies of the various components. In this
case, the power cable efficiency is 98.47%, the drive assembly efficiency is
96.17%, the motor efficiency is 77.4%, and the pump mechanical efficiency is
85.64%.
Finally, open the Drive Equipment output window to examine the relevant
operating and performance parameters of each of the system components.
The drive assembly is loaded below any of its limits with respect to thrust,
torque, power, and speed. The motor is loaded to 61.8% of its full load at the
50.7 Hz operating frequency. Results from the use of motor performance
curves show an operating speed of 1440 RPM, efficiency of 77.4%, power
factor of 0.6, slip of 83 RPM, and winding temperature of 126.4C, well below
the maximum rated winding temperature of 204.4C.

You are here: Sample Sessions > Session 9: Heat Transfer Module

Session 9: Heat Transfer Module

Note: Sample Session 9 is based on PCPUMP v3.4.
This sample session will show you how to use the heat transfer option in
PCPUMP. The session reinforces the concepts presented in sessions 1-4 and
introduces the rod string space out thermal effects window using a ground
temperature profile.

Scenario:
A horizontal heavy oil well is equipped with a surface-driven KUDU Industries
Inc. 42K1800 pump. The effect of temperature on oil viscosity is known, but
the temperature of the produced fluid is not. The ground temperature at the
perforations and at the surface is known. The PC pump is seated in the tangent
section at 1000 mKB. The tangent section spans from 980 mKB to 1020 mKB.
The maximum flow rate without exceeding equipment specifications is to be
determined. Based on previous experience with wells in this field, it is
expected that the flow rate will be in the range of 60 to 80 m3/D .

Objective:
Without knowing the produced fluid temperature, determine the maximum
flow rate that can be achieved without exceeding the following limits:
250 RPM maximum speed
80% maximum pump pressure loading
70% maximum rod torque load

Data:
Wellbore Geometry
Well Type: Horizontal
System Configuration:
Pump Seating Depth: 1000 mKb
Mid-Perforations: 1365 mKB
Production Casing: 139.7 mm x 25.3 kg/m (1365 m), 45 W/mK
Intermediate Casing: 168.3 mm x 29.76 kg/m (500 m), 45 W/mK

Surface Casing: 219.1 mm x 35.72 kg/m (200 m), 45 W/mK

Ground: Sandstone (1865 m), 250 mm hole diameter, 30 days from start
of production
Tubing: 88.9 mm x 13.8 kg/m, 45 W/mK
Rod String: PRO-ROD 22.2 mm, 620 C continuous rods
PC Pump: KUDU Industries Inc. (42K1800)
- seated in tangent section
- displacement = 0.420 m3/D/RPM
- pressure rating = 18000 kPa
- pump friction = 100 Nm
- volumetric efficiency = 85%
Fluid Properties:
Fluid Composition
Water Cut: 0%
Sand Cut: 0%
Gas Specific Gravity: 0.7
Oil API Gravity: 9API
Fluid Viscosity
Fluid Viscosity: Temperature versus viscosity data available
Operating Conditions:
Fluid Rate: target = 60 to 80 m3/D
Fluid Level: 900 mKB
Tubing Head Pressure: 500 kPa
Casing Head Pressure: 500 kPa
Ground Temperature: 45C @ 1365 mKB, 5C @ 0 mKB

Procedure:
To perform an analysis with heat transfer, go to the Options tab and select
Consider heat transfer model in calculating temperature profile of produced fluids. The current
version of the heat transfer module can only be used in limited circumstances
where a single-phase fluid is selected, the pump is above the perforations and
the PCP system is surface driven.
Navigate to the Wellbore Geometry tab. Import the Sample Session 9 wellbore

geometry by clicking the Import button, selecting the file type '.xml' then
selecting the "samps9.xml" file from your default Wellbore file directory. The
window will be updated with the survey data and appear as shown below.

Wellbore Geometry Window

Move to the Equipment Configuration tab to specify the system configuration.

Enter the Pump Seating Measured Depth of 1000 mKB so that the PCP is
landed in the tangent section. For a horizontal well, you may consider the MidPerforations Measured Depth to be the beginning of the horizontal section,
which at a measured depth of 1365 mKB in this well. Enter these two
locations in the appropriate input fields.
Next, open the Pump Selection window and select a Kudu Industries 42K1800
pump with a Pump Friction torque of 100 Nm and a Volumetric Efficiency of
85%. Close the Pump Selection window to return to the Equipment
Configuration window.
Click the Tubulars update button
in the Equipment Configuration window.
With heat transfer activated, there will be four tabs along the top of the
window labelledProduction Casing, Intermediate Casing, Surface Casing and
Ground. The window should appear as below:

Tubular Selection Window - Heat Transfer Activated

Specify 1865 m of 139.7 mm x 23.07 kg/m production casing, 500 m of

168.3 mm x 29.76 kg/m intermediate casing, and 200 m of 219.1 mm x
35.72 kg/m surface casing. Enter a Thermal Conductivity of 45 W/mK (typical
value for steel) and "Cement" as the Surrounding Material for all three casing
types. The thermal conductivity value entered is for the casing material, and
the surrounding material refers to the material immediately outside of the
casing.
Switch to the Ground tab and select 1865 m of Sandstone with a hole
diameter of 250.8 mm and 30 days from the start of production. The Time
From Start of Production (days) is used to determine how much heat has
already been transferred from the produced fluid to the surrounding ground at
the time you are performing the PC-PUMP system analysis. Click the OK button
to finish in the Tubulars update window. It is recommended that a Time From

Start of Production of at least 30 days be entered in order to reflect a case

where the heat transfer will be relatively constant with time. At this point, the
temperature of the ground surrounding the wellbore will be approaching a
more constant value, and the change in heat transfer with time will have a
less significant impact on the results.
Next, select 996 m of 88.9 mm x 13.8 kg/m tubing with a Thermal
Conductivity of 45 W/mK, and then finish the downhole equipment selection
by adding PRO-ROD 22.2 mm 620 C continuous rods.

Equipment Configuration Window

Move to the Fluid Properties window and select the Calculate Fluid Density option.
Enter a Water Cut of 0%, Sand Cut of 0%, Gas Specific Gravity of 0.7, and Oil
API Gravity of 9API. Leave the tubing and casing density factors at their
default value of 1.00.

Fluid Properties Window

Next, select Use Advanced Viscosity and enter the following temperature versus
viscosity data into the table:
Temperature

Viscosity

10C

20000
cp

20C

6000 cp

30C

2000 cp

40C

1000 cp

Finish entering the fluid properties by clicking the Thermal Properties tab,

choosing the
button.

Derived from Fluid Composition

option and clicking the

Use Default Values

Move to the Operating Conditions window and specify a Produced Fluid Flow
Rate (surface) of 60 m3/D , Fluid Level of 900 mKB, and tubing and casing
head pressures of 500 kPa. Select Specify Temperature Profile and enter the
following ground temperature profile into the Temperature Profile window:
Measured
Depth

Temperature

0 mKB

5C

1365
mKB

45C

The temperature profile window should appear as below:

Temperature Profile Window - Heat Transfer Activated

In order to determine the maximum flow rate without exceeding equipment

specifications, perform a batch analysis with Fluid Flow Rate ranging from 60
to 80 m3/D with an increment of 2 m3/D . Click Calculate to run the system
analysis. Scroll the batch analysis to 76 m3/D , which corresponds to the
maximum flow rate that does not exceed the design specifications of 250 RPM
maximum pump speed, 80% maximum pump pressure loading and 70%
maximum rod torque loading. At a flow rate of 76 m3/D , the pump speed will
be 212.9 RPM, the pump pressure loading will be 55.17%, and the maximum
rod torque loading will be 69.74%. The analysis results Summary tab is shown
below.

Analysis Results Window

To examine the temperature profile in more detail, select the "Temperature

and Viscosity Profiles" graph in the Basic Fluid Flow tab. The produced fluid
temperature is calculated with the heat transfer module, and graphically

displayed as shown below. The fluid temperature is 45C at the Mid

Perforations, 44.6C at the pump intake and discharge (heat generated in the
pump is assumed to be negligible in this case) and 34.8C at the wellhead on
the tubing side. These temperatures are calculated based on radiation,
convection and conduction heat losses through the tubing and casing to the
surrounding ground. The temperature values can be verified in the Key
Locations tab.

Basic Fluid Flow Tab - Heat Transfer Analysis Results

Select the Rod Loading/Deflection tab and scroll to the "Rod String Space Out"
graph. The effect of thermal expansion on the space out can be calculated from
the ground temperature profile when it has been input in the Operating
Conditions tab. Click the Specify Thermal Effects button and select Consider thermal
expansion effects on space-out. Since a ground temperature is entered in the
Operating Conditions tab, the Thermal Effects window indicates that PC-PUMP is
using the ground temperature profile. Click the OK button to view the results.
Note that if no ground temperature profile is entered, the effects of thermal
expansion/contraction on rod string space out can be calculated using an
average ground temperature (see Sample Session 2 for more details). The
minimum space out including thermal effects should be 623.7 mm.

Rod String Space-out Thermal Effect Pop-Up - Ground Temperature Profile Entered

Rod String Space Out - Ground Temperature Profile Used

The heat transfer module can currently only be used in limited circumstances
where the user must select a single-phase fluid, use a surface driven PCP, and
have the pump above the perforations. Please contact C-FER for any suggested
improvements and expansion of the heat transfer module if you require
additional functionality beyond what is included in this version of the software.
Any user input regarding future development of the heat transfer module is
appreciated.

Related Topics
Heat Transfer Module
Heat Transfer Help

You are here: Sample Sessions > Session 10: Time Series Calculations

Session 10: Time Series Batch Analysis

Note: Sample Session 10 is based on PCPUMP v3.5. If you are using a later
version of the program, or an updated database, some of the results you get
may not be the same. Also, some of the equipment selected in this Help File
may no longer be available in the database. If this is the case, select the
closest match available.
This sample session will demonstrate how to use the time series Batch Analysis
option in PCPUMP. The production date input in the Batch Analysis window as
well as the Time Series Results tab in the Analysis Comparison Window will be
shown.

Scenario:
The pump speed of a PCP system in a vertical oil well has been increased twice
in the last month to increase production. There are no downhole gauges
installed in the well to determine how much fluid is above the pump and fluid
level shots aren't readily available.

Objective:
Data collected from the well over the time period of July 16, 2015 to August
16, 2015 is to be analyzed to confirm that recent changes in pump speed have
not caused the submergence to drop below 50 m above the pump.

Data:
Wellbore Geometry
Well Type: Vertical
System Configuration:
Pump Seating Depth: 900 mKb
Mid-Perforations: 880 mKB
Production Casing: 177.8 mm x 25.3 kg/m
Tubing: 101.6 mm x 16.37 kg/m
Rod String: AOT 25.4 mm grade 78 standard rods with slimhole couplings
PC Pump: Oil Lift 100-1200 STD2
- displacement = 1.0 m3/D/RPM

- pressure rating = 11748 kPa

- pump friction = 100 Nm
- volumetric efficiency = 85%
Fluid Properties:
Fluid Composition
Water Cut: 20%
Sand Cut: 0%
Gas Specific Gravity: 0.7
Oil API Gravity: 18API
Fluid Viscosity
Fluid Viscosity: 100 cp
Operating Conditions:
The following production data is available from the well:
Tubing Head Pressure: 100 kPa
Casing Head Pressure: 100 kPa
Bottomhole Temperature: 30 C
Temperature Gradient: 1 C /100 m
Production data available (table below)

Procedure:
Start in the Equipment Configuration tab to specify the system configuration.
Enter the Pump Seating Measured Depth of 900 mKB and a Mid-Perforations
Measured Depth of 880 mKB.
Next, open the Pump Selection window and select a Oil Lift 100-1200 STD2
pump with a Pump Friction torque of 100 Nm and a Volumetric Efficiency of
85%. Leave the Pump Selection window by pressing OK and return to the
Equipment Configuration window.
Click the Tubulars update button
in the Equipment Configuration window.
Continue by specifying 900 m of 177.8 mm x 25.30 kg/m casing and 892.1 m
of 101.6 mm x 16.37 kg/m tubing.
Finish the downhole equipment selection by adding AOT 25.4 mm Grade 78

standard rods with 25.4 mm API slimhole couplings (7.62 m length).

Equipment Configuration Window

Move to the Fluid Properties window and select the Calculate Fluid Density option.
Enter a Water Cut of 20%, Sand Cut of 0%, Gas Specific Gravity of 0.7, Oil API
Gravity of 18API and a Total Fluid Viscocity of 100 cp. Leave the tubing and
casing density factors at their default value of 1.00.

Fluid Properties Window

Next, move to the Operating Conditions tab, check the Specify IPR data box at
the top of the window and then click the Specify button. Choose the Straight Line
(with Data Point) relationship and then enter the following test data:
Static Reservoir Pressure: 8000 kPa
Test Point #1-Producing Pressure: 3000 kPa
Test Point #1-Fluid Rate: 100 m3/D
Once you have specified your IPR, click the OK button to return to the
Operating Conditions window. Specify a Produced Fluid Flow Rate (surface) of
100 m3/D ,and tubing and casing head pressures of 100 kPa. Click Specify
Temperature and enter a Bottomhole Temperature of 30C and a Temperature
Gradient of 1C/100 m to describe the temperature profile of the well.

Operating Conditions Window

To enter production data with dates, you can use the Batch Analysis tool.
Check the Perform Batch Analysis box in the Batch Parameter area under the Case
Manager. Then click on the update button
to the right of the Parameter field
which will bring up the Batch Parameter window. Check the box next to Fluid
Flow Rate and Pump Speed from the Parameters area and then check the
Specify Time Series Data box. Next, enter the following production data in the
table (you can use the SS_10_Data.csv file found at C:\Users\

[USER NAME]\PC-PUMP3\User to copy and paste the data into the table).
Date

Fluid Rate (m3/D)

Pump Speed (RPM)

16/07/2015

100

100

17/07/2015

102

100

18/07/2015

101

100

19/07/2015

98

100

20/07/2015

104

100

21/07/2015

103

100

22/07/2015

106

100

23/07/2015

104

100

24/07/2015

102

100

25/07/2015

125

140

26/07/2015

140

140

27/07/2015

142

140

28/07/2015

139

140

29/07/2015

141

140

30/07/2015

141

140

31/07/2015

140

140

01/08/2015

138

140

02/08/2015

140

140

03/08/2015

142

140

04/08/2015

140

140

05/08/2015

142

140

06/08/2015

141

140

07/08/2015

143

140

08/08/2015

145

140

09/08/2015

144

140

10/08/2015

143

140

11/08/2015

142

140

12/08/2015

144

140

13/08/2015

150

160

14/08/2015

155

160

15/08/2015

157

160

16/08/2015

157

160

Once the data has been entered, the window should appear as below:

Batch Parameters Window

NOTE: In cases where input parameters might conflict (such as when Fluid
Flow Rate and Pump Speed are entered) PCPUMP will use the value entered in
the furthest left column of the table to calculate results, and will provide a
comparison between the input and calculated value for the other parameter(s).
To change the order of the columns, simply click and drag the column headers.
Press OK to finish entering data in the Batch Parameter window. Click the
Calculate button. The analysis Analysis Comparison Window should appear as
shown below:

Analysis Comparison Window

Navigate to the Time Series Results tab. In this tab, you can customize the
values displayed on the primary and secondary y-axes of the graph. Calculated
values appear as solid lines while input values appear as dashed lines. Just like
in the Table and Chart tabs of the Analysis Comparison window, the available
parameters that appear in the Primary Y-Axis and Secondary Y-Axis areas can
be customized using the Options tab. Select Fluid Flow Rate and Pump Speed
on the primary y-axis and Submergence on the secondary y-axis. The window
should appear as below:

Time Series Results

The graph shows a drop in the submergence (or fluid level) following the two
pump speed changes. The calculated pump speed is close to but generally
higher than the input pump speed, possibly due to the downhole volumetric
efficiency being higher than expected. If the downhole volumetric efficiency is
higher than expected due to temperature or fluid swell, the accuracy of the
model could be improved by changing the Volumetric Efficiency in the Pump

Selection area of the Equipment Configuration window.

An analysis of the graph indicates that the submergence has dropped below
the prescribed minimum of 50 m following the most recent increase in pump
speed. Based on this information, it may be beneficial to decrease the pump
speed to ensure there is sufficient fluid above the pump.
This sample session has illustrated how the Batch Parameter analysis can be
used to perform time series calculations on multiple input parameters. This
allows users to quickly evaluate the consequences of implementing changes to
the operating conditions of a well. By evaluating the system over time, it is
easy to observe trends and detect problems.

Related Topics
Analysis Configuration
Case Manager
Analysis Inputs Overview
Using Tables and Charts
Printing Reports

You are here: Auxillary Analysis > ESPBend Overview

ESPBend Overview
Note: The ESPBend tool is currently in Beta testing. Please contact CFER if you would like to use the ESPBend module in PC-PUMP.
C-FER has developed a beta version of ESPBend (deployed within C-FER's PCPUMP software) based on previous work summarized in the technical paper
Assessing Equipment Damage During Installation of ESP Assemblies in
Deviated Wellbores (Zahacy et al. 2000) prepared for the 2000 SPE ESP
Workshop in Houston, April 26-28, 2000.
The program uses an iterative Finite Element Analysis (FEA) model to
determine the contact points and forces between the ESP system and the well
casing, as well as the curvature, deflection and stress along the length of the
ESP system.
The results are presented in graphical format, which the user can use to
determine if the calculated parameters have exceeded predetermined limits.
The program can be used to verify the limitations of an ESP system before
installation, compare the maximum bending and stress in alternative designs
and analyze the possible cause of failure for a system installed in a deviated
well.

You are here: Auxillary Analysis > ESPBend Analysis Inputs

ESPBend Equipment Inputs

Note: The ESPBend tool is currently in Beta testing. Please contact CFER if you would like to use the ESPBend module in PC-PUMP.
Note: The ESPBend calculation is conducted independently of the main
calculation loop and will only function if you have already completed
the primary analysis and have entered a wellbore profile.
The ESPBend equipment inputs are located in the Auxiliary Analysis tab of
PCPUMP.

ESPBend Input Window

Specifying Equipment
The ESP-BEND equipment selection window is used to select ESP equipment
from the database. In order to perform an analysis, all of the following
information is required:
Casing
One casing size can be selected from the drop-down list next to the Casing
label. Information about the selected casing is displayed as:
Diameter x Weight [Part Number]

Tubing
One tubing size can be selected from the drop-down list next to the Tubing
label. Information about the selected tubing is displayed as:
Diameter x Weight, Tubing Grade, Connection Type [Part Number]
Bolt-On Head
One bolt-on head can be selected from the drop-down list next to the BoltOn Head label. Information about the selected bolt-on head is displayed

as:
Vendor: Bolt-On Head Series, Bolt-On Head Model, [Part Number]
Pumps
One or more pumps can be selected in the Pumps selection area.
Information about the selected pump will be displayed as:
Vendor: Pump Series, Pump Model, Housings, Standard/Abrasion
Resistant, F (floater)/C (compression) [Part Number]
After a pump is selected, a new row will be added to the table to enable
the user to select additional pumps if necessary. By right-clicking in the
Pumps selection area, a new row can be inserted between rows, a single
row can be deleted, or all rows can be cleared.

Pump Selection Window With Multiple Pumps Selected

Bolt-On Intake
One bolt-on intake can be selected from the drop-down list next to the
Bolt-On Intake label. Information about the selected bolt-on intake series
is displayed as:
Vendor: Intake
Number]

Series,

Standard/Abrasion

Resistant

[Part

Seal/Protector
One or more seals/protectors can be selected in the Seal/Protector
selection area. Information about the selected seal/protector will be
displayed as:
Vendor: Seal/Protector Series, Seal/Protector Model, Housings,
Standard/Abrasion Resistant [Part Number]
After a seal/protector is selected, a new row will be added to the table to
enable the user to select additional seals/protectors if necessary. By rightclicking in the Seal/Protector selection area, a new row can be inserted

between rows, a single row can be deleted, or all rows can be cleared.

Seal/Protector Selection Window With Multiple Seals Selected

Motors
One or more motors can be selected in the Motors selection area.
Information about the selected motor will be displayed as:
Vendor: Motor Series, Motor Model, Motor Configuration, Power @
60Hz (HP) [Part Number]
After a motor is selected, a new row will be added to the table to enable
the user to select additional motors if necessary. By right-clicking in the
Motors selection area, a new row can be inserted between rows, a single
row can be deleted, or all rows can be cleared.

Motor Selection Window With Multiple Motors Selected

Calculating an ESPBend Case

Once all equipment information is entered, an ESPBend case can be calculated
by pressing the Calculate button on the left-side of the ESP-BEND tab:

You are here: Auxillary Analysis > ESPBend Analysis Outputs

ESPBend Analysis Outputs

Note: The ESPBend tool is currently in Beta testing. Please contact CFER if you would like to use the ESPBend module in PC-PUMP.
Within the ESP-Bend Results window, a drop-down list allows you to access the
following information at the specified Survey Interval:
Deflected Shape: Graphical representation of the casing boundaries,
casing center, ESP start coordinates and ESP final coordinates used to
determine if bending is occurring and how many contact points there are.

Shape Relative to Casing in plane of curvature: Graphical representation

of the casing inner diameter, tubing/ESP outer diameter and tubing/ESP
outer diameter in the plane of curvature used to show curvature along the
length of the ESP system and how many contact points there are.

Shape perpendicular to plane of curvature: Graphical representation of

the casing inner diameter, tubing/ESP outer diameter and tubing/ESP
outer diameter perpendicular to the plane of curvature used to show
curvature along the length of the ESP system and how many contact
points there are.

Shear vs. Length: Graphs that displays the shear force along the length of
the ESP.

Moment vs. Length: Graphs that displays the bending moment along the
length of the ESP.

Stress vs. Length: Graph that displays the calculated stress and the stress
limit along the length of the ESP system. This graph can be used to
determine if the calculated stress exceeds the stress limit at a given
"Survey Interval".

Curvature vs. Length: Graph that displays the calculated curvature and
the curvature limit along the length of the ESP system. This graph can be
used to determine if the calculated curvature exceeds the curvature limit
at a given "Survey Interval".

Stiffness and Diameter: Graph that displays the stiffness and outer
diameter along the length of the ESP system.

The Survey Interval can be changed to show the results of the above graphs at
various measured depths. It is recommended that the results of the calculation
be reviewed along the entire length of the wellbore to ensure that stress and
curvature limits are not exceeded at any depth.

You are here: Auxillary Analysis > ESPBend Custom Bolt-On Head

ESPBend Custom Bolt-On Head

Note: The ESPBend tool is currently in Beta testing. Please contact CFER if you would like to use the ESPBend module in PC-PUMP.
You can create new bolt-on head models that can be added to your own custom
databases. These bolt-on heads can subsequently be selected and used in the
same manner as any of the bolt-on heads included in the ESPBend equipment
database.
You can add custom bolt-on heads by opening the
selecting "Custom Equipment".

Tools

menu option and

Custom Equipment Window

Specifying Custom Bolt-On Head Information

1. On the left-side of the Custom Equipment window, you can select a custom
bolt-on head database. Each database may contain one or more custom
bolt-on head models. Once a database is selected, the names of these
models will appear under it. Highlighting a particular bolt-on head model
will display the specifications of the selected model. If an existing bolt-on
head model is selected to be edited, proceed to Step 4.
2. To create a new custom bolt-on head database, select "Bolt-On Head" and
click the Add File button. This will bring up a window into which you must
enter a Bolt-On Head Description and a File Name. Although a file name is
automatically created, you can modify it within the lower edit box. When
finished, click the OK button.

New File: Custom Bolt-On Head Window

3. Once a file has been created, new custom bolt-on head models can be
created by right-clicking on the file name and selecting the "Add Model"
option. Alternatively, you can duplicate an exiting model by selecting a
bolt-on head model, right-clicking, and selecting "Duplicate Model". When
you have added a new model to the file, you can enter or update the

model specifications located on the right-side of the screen.

Custom Bolt-On Head Model Input Window

4. The following specifications are required for custom bolt-on heads:

Series: Series of custom bolt-on head from vendor catalog (e.g. 375,
400, 500).
Part Number: Part number from vendor catalog.
Length: Length of the bolt-on head from vendor catalog.
Weight: Weight of the bolt-on head from vendor catalog.
Custom bolt-on heads are entered in one or more elements to simulate the
change in stiffness of the component along its length. Elements are subsections of a complete component that capture changes in outer or inner
diameter of the component. A new element should be created for any
significant change in outer or inner diameter of the component that will
result in a change in stiffness. Contact C-FER for more detailed information
on obtaining and entering this information.
Component Element Length: Length of the element.
Component Element Outer Diameter: Outer diameter of the element.
Component Element Inner Diameter: Inner diameter of the element.
Component Element Weight: Weight of the element.
Component Element EI: Bending stiffness of the element.
Component Element AE: Axial stiffness of the element.
Component Element GJ: Torsional stiffness of component.
Component Maximum Curvature:
Maximum curvature that the
element can withstand.
Component Maximum Stress: Maximum stress that the element can
withstand.
5. To remove a bolt-on head from a database, select it by highlighting its
name, right-click the mouse and select "Delete Model".
Once you have finished, click OK to close the Custom Equipment input
window. All of the new custom bolt-on head databases and their
corresponding bolt-on head models will now be available for selection and use
in the ESPBend equipment database.

You are here: Auxillary Analysis > ESPBend Custom Bolt-On Intake

ESPBend Custom Bolt-On Intake

Note: The ESPBend tool is currently in Beta testing. Please contact CFER if you would like to use the ESPBend module in PC-PUMP.
You can create new bolt-on intake models that can be added to your own
custom databases. These bolt-on intakes can subsequently be selected and
used in the same manner as any of the bolt-on intakes included in the
ESPBend equipment database.
You can add custom bolt-on intakes by opening the
selecting "Custom Equipment".

Tools

menu option and

Custom Equipment Window

Specifying Custom Bolt-On intake Information

1. On the left-side of the Custom Equipment window, you can select a custom
bolt-on intake database. Each database may contain one or more custom
bolt-on intake models. Once a database is selected, the names of these
models will appear under it. Highlighting a particular bolt-on intake model
will display the specifications of the selected model. If an existing bolt-on
intake model is selected to be edited, proceed to Step 4.
2. To create a new custom bolt-on intake database, select "Bolt-On intake"
and click the Add File button. This will bring up a window into which you
must enter a Bolt-On Intake Description and a File Name. Although a file
name is automatically created, you can modify it within the lower edit
box. When finished, click the OK button.

New File: Custom Bolt-On Intake Window

3. Once a file has been created, new custom bolt-on intake models can be
created by right-clicking on the file name and selecting the "Add Model"
option. Alternatively, you can duplicate an exiting model by selecting a
bolt-on intake model, right-clicking, and selecting "Duplicate Model". When
you have added a new model to the file, you can enter or update the

model specifications located on the right-side of the screen.

Custom Bolt-On Intake Model Input Window

4. The following specifications are required for custom bolt-on intakes:

Series: Series of custom bolt-on intake from vendor catalog (e.g. 375,
400, 500).
Standard or Abrasion Resistant: Indication of whether the intake
contains abrasion resistant materials or not.
Part Number: Part number from vendor catalog.
Outer Diameter: Indication of whether pump contains abrasion
resistant materials or not.
Length: Length of the bolt-on intake from vendor catalog.
Weight: Weight of the bolt-on intake from vendor catalog.
Custom bolt-on intakes are entered in one or more elements to simulate
the change in stiffness of the component along its length. Elements are
sub-sections of a complete component that capture changes in outer or
inner diameter of the component. A new element should be created for
any significant change in outer or inner diameter of the component that
will result in a change in stiffness. Contact C-FER for more detailed
information on obtaining and entering this information.
Component Element Length: Length of the element.
Component Element Outer Diameter: Outer diameter of the element.
Component Element Inner Diameter: Inner diameter of the element.
Component Element Weight: Weight of the element.
Component Element EI: Bending stiffness of the element.
Component Element AE: Axial stiffness of the element.
Component Element GJ: Torsional stiffness of component.
Component Maximum Curvature:
Maximum curvature that the
element can withstand.
Component Maximum Stress: Maximum stress that the element can
withstand.
5. To remove a bolt-on intake from a database, select it by highlighting its
name, right-click the mouse and select "Delete Model".

Once you have finished, click OK to close the Custom Equipment input
window. All of the new custom bolt-on intake databases and their
corresponding bolt-on intake models will now be available for selection and
use in the ESPBend equipment database.

You are here: Auxillary Analysis > ESPBend Custom Casing

ESPBend Custom Casing

Note: The ESPBend tool is currently in Beta testing. Please contact CFER if you would like to use the ESPBend module in PC-PUMP.
You can create new casing models that can be added to your own custom
databases. The casing can subsequently be selected and used in the same
manner as any of the casing included in the ESPBend equipment database.
You can add custom casing by opening the
"Custom Equipment".

Tools

menu option and selecting

Custom Equipment Window

Specifying Custom Casing Information

1. On the left-side of the Custom Equipment window, you can select a custom
casing database. Each database may contain one or more custom casing
models. Once a database is selected, the names of these models will
appear under it. Highlighting a particular casing model will display the
specifications of the selected model. If an existing casing model is selected
to be edited, proceed to Step 4.
2. To create a new custom casing database, select "casing" and click the Add
File button. This will bring up a window into which you must enter a Casing
Description and a File Name. Although a file name is automatically
created, you can modify it within the lower edit box. When finished, click
the OK button.

New File: Custom Casing Window

3. Once a file has been created, new custom casing models can be created by
right-clicking on the file name and selecting the "Add Model" option.
Alternatively, you can duplicate an exiting model by selecting a casing
model, right-clicking, and selecting "Duplicate Model". When you have
added a new model to the file, you can enter or update the model
specifications located on the right-side of the screen.

Custom Casing Model Input Window

4. The following specifications are required for custom casing:

Part Number: Unique part number.
Casing OD: Outer diameter of casing body.
Casing Weight: Weight of the casing per unit length.
Casing ID: Inner diameter of the casing body.
Custom casing is entered in one or more elements to simulate the change
in stiffness of the component along its length. Elements are sub-sections of
a complete component that capture changes in outer or inner diameter of
the component. A new element should be created for any significant
change in outer or inner diameter of the component that will result in a
change in stiffness. Contact C-FER for more detailed information on
obtaining and entering this information.
Component Element Length: Length of the element.
Component Element Outer Diameter: Outer diameter of the element.
Component Element Inner Diameter: Inner diameter of the element.
Component Element Weight: Weight of the element.
Component Element EI: Bending stiffness of the element.
Component Element AE: Axial stiffness of the element.
Component Element GJ: Torsional stiffness of component.
Component Maximum Curvature:
Maximum curvature that the
element can withstand.
Component Maximum Stress: Maximum stress that the element can
withstand.
5. To remove casing from a database, select it by highlighting its name, rightclick the mouse and select "Delete Model".
Once you have finished, click OK to close the Custom Equipment input
window. All of the new custom casing databases and their corresponding
casing models will now be available for selection and use in the ESPBend
equipment database.

You are here: Auxillary Analysis > ESPBend Custom Motor

ESPBend Custom Motor

Note: The ESPBend tool is currently in Beta testing. Please contact CFER if you would like to use the ESPBend module in PC-PUMP.
You can create new motor models that can be added to your own custom
databases. These motors can subsequently be selected and used in the same
manner as any of the motors included in the ESPBend equipment database.
You can add custom motors by opening the
"Custom Equipment".

Tools

menu option and selecting

Custom Equipment Window

Specifying Custom Motor Information

1. On the left-side of the Custom Equipment window, you can select a custom
motor database. Each database may contain one or more custom motor
models. Once a database is selected, the names of these models will
appear under it. Highlighting a particular motor model will display the
specifications of the selected model. If an existing motor model is selected
to be edited, proceed to Step 4.
2. To create a new custom motor database, select "motor" and click the Add
File button. This will bring up a window into which you must enter a Motor
Description and a File Name. Although a file name is automatically
created, you can modify it within the lower edit box. When finished, click
the OK button.

New File: Custom Motor Window

3. Once a file has been created, new custom motor models can be created by
right-clicking on the file name and selecting the "Add Model" option.
Alternatively, you can duplicate an exiting model by selecting a motor
model, right-clicking, and selecting "Duplicate Model". When you have
added a new model to the file, you can enter or update the model
specifications located on the right-side of the screen.

Custom Motor Model Input Window

4. The following specifications are required for custom motors:

Series: Series of custom motor from vendor catalog (e.g. 375, 400,
500).
Part Number: Part number from vendor catalog.
Motor Configuration: Configuration of motor (Single, Upper, Central or
Lower Tandem).
Power: Motor power @60Hz from vendor catalog.
Voltage: Motor voltage @60Hz from vendor catalog.
Current: Motor current from vendor catalog.
Length: Length of the motor from vendor catalog.
Weight: Weight of the motor from vendor catalog.
Number of nodes: Number of nodes is the number of elements (see
below) plus 1.
Custom motors are entered in one or more elements to simulate the
change in stiffness of the component along its length. Elements are subsections of a complete component that capture changes in outer or inner
diameter of the component. A new element should be created for any
significant change in outer or inner diameter of the component that will
result in a change in stiffness. Contact C-FER for more detailed information
on obtaining and entering this information.
Component Element Length: Length of the element.
Component Element Outer Diameter: Outer diameter of the element.
Component Element Inner Diameter: Inner diameter of the element.
Component Element Weight: Weight of the element.
Component Element EI: Bending stiffness of the element.
Component Element AE: Axial stiffness of the element.
Component Element GJ: Torsional stiffness of component.
Component Maximum Curvature:
Maximum curvature that the
element can withstand.
Component Maximum Stress: Maximum stress that the element can
withstand.
5. To remove a motor from a database, select it by highlighting its name,

right-click the mouse and select "Delete Model".

Once you have finished, click OK to close the Custom Equipment input
window. All of the new custom motor databases and their corresponding
motor models will now be available for selection and use in the ESPBend
equipment database.

You are here: Auxillary Analysis > ESPBend Custom Pump

ESPBend Custom Pump

Note: The ESPBend tool is currently in Beta testing. Please contact CFER if you would like to use the ESPBend module in PC-PUMP.
You can create new pump models that can be added to your own custom
databases. These pumps can subsequently be selected and used in the same
manner as any of the pumps included in the ESPBend equipment database.
You can add custom pumps by opening the
"Custom Equipment".

Tools

menu option and selecting

Custom Equipment Window

Specifying Custom Pump Information

1. On the left-side of the Custom Equipment window, you can select a custom
pump database. Each database may contain one or more custom pump
models. Once a database is selected, the names of these models will
appear under it. Highlighting a particular pump model will display the
specifications of the selected model. If an existing pump model is selected
to be edited, proceed to Step 4.
2. To create a new custom pump database, select "pump" and click the Add File
button. This will bring up a window into which you must enter a Pump
Description and a File Name. Although a file name is automatically
created, you can modify it within the lower edit box. When finished, click
the OK button.

New File: Custom Pump Window

3. Once a file has been created, new custom pump models can be created by
right-clicking on the file name and selecting the "Add Model" option.
Alternatively, you can duplicate an exiting model by selecting a pump
model, right-clicking, and selecting "Duplicate Model". When you have
added a new model to the file, you can enter or update the model
specifications located on the right-side of the screen.

Custom Pump Model Input Window

4. The following specifications are required for custom pumps:

Pump Series: Series of custom pump from vendor catalog (e.g. 375,
400, 500).
Standard or Abrasion Resistant: Indication of whether pump contains
abrasion resistant materials or not.
Part Number: Part number from vendor catalog.
Housing: Housing number from vendor catalog.
Length: Length of the pump from vendor catalog.
Weight: Weight of the pump from vendor catalog.
Number of Nodes: Number of nodes is the number of elements (see
below) plus 1.
Number of Stages: Number of pump stages from vendor catalog.
Impeller Type: F - Floating, C - Compression.
Pump OD: Pump outer diameter from vendor catalog.
Pump Housing OD: Pump housing outer diameter from vendor catalog.
Minimum Casing ID: Minimum casing inner diameter that the pump can
be run in.
Shaft Diameter: Pump shaft diameter.
Std Shaft Limit: Shaft power limit for standard shaft.
High Strength Shaft Limit: Shaft power limit for high strength shaft.
Housing Pressure Limit: Pressure limit of pump housing.
Rotation Direction: Direction of pump rotation (Clockwise or counterclockwise).
Max Staging Shaft Std: Maximum number of stages when using a
standard shaft.
Max Staging Thrust Bearing Std: Maximum number of stages when
using standard thrust bearings.
Max Staging HL Thrust Bearing Std:Maximum number of stages when
using high load thrust bearings.
Max Staging HS Shaft Std: Maximum number of stages when using a
high strength shaft.
Custom pumps are entered in one or more elements to simulate the
change in stiffness of the component along its length. Elements are sub-

sections of a complete component that capture changes in outer or inner

diameter of the component. A new element should be created for any
significant change in outer or inner diameter of the component that will
result in a change in stiffness. Contact C-FER for more detailed information
on obtaining and entering this information.
Component Element Length: Length of the element.
Component Element Outer Diameter: Outer diameter of the element.
Component Element Inner Diameter: Inner diameter of the element.
Component Element Weight: Weight of the element.
Component Element EI: Bending stiffness of the element.
Component Element AE: Axial stiffness of the element.
Component Element GJ: Torsional stiffness of component.
Component Maximum Curvature:
Maximum curvature that the
element can withstand.
Component Maximum Stress: Maximum stress that the element can
withstand.
5. To remove a pump from a database, select it by highlighting its name,
right-click the mouse and select "Delete Model".
Once you have finished, click OK to close the Custom Equipment input
window. All of the new custom pump databases and their corresponding pump
models will now be available for selection and use in the ESPBend equipment
database.

You are here: Auxillary Analysis > ESPBend Custom Seal/Protector

ESPBend Custom Seal/Protector

Note: The ESPBend tool is currently in Beta testing. Please contact CFER if you would like to use the ESPBend module in PC-PUMP.
You can create new seal/protector models that can be added to your own
custom databases. These seal/protectors can subsequently be selected and
used in the same manner as any of the seals/protectors included in the
ESPBend equipment database.
You can add custom seals/protectors by opening the
selecting "Custom Equipment".

Tools

menu option and

Custom Equipment Window

Specifying Custom Seal/Protector Information

1. On the left-side of the Custom Equipment window, you can select a custom
seal/protector database. Each database may contain one or more custom
seal/protector models. Once a database is selected, the names of these
models will appear under it. Highlighting a particular seal/protector model
will display the specifications of the selected model. If an existing
seal/protector model is selected to be edited, proceed to Step 4.
2. To create a new custom seal/protector database, select "seal/protector"
and click the Add File button. This will bring up a window into which you
must enter a Seal/Protector Description and a File Name. Although a file
name is automatically created, you can modify it within the lower edit
box. When finished, click the OK button.

New File: Custom Seal/Protector Window

3. Once a file has been created, new custom seal/protector models can be
created by right-clicking on the file name and selecting the "Add Model"
option. Alternatively, you can duplicate an exiting model by selecting a
seal/protector model, right-clicking, and selecting "Duplicate Model". When
you have added a new model to the file, you can enter or update the

model specifications located on the right-side of the screen.

Custom Seal/Protector Model Input Window

4. The following specifications are required for custom seal/protectors:

Series: Series of custom seal/protector from vendor catalog (e.g. 375,
400, 500).
Standard or Abrasion Resistant: Indication of whether the
seal/protector contains abrasion resistant materials or not.
Part Number: Part number from vendor catalog.
Length: Length of the seal/protector from vendor catalog.
Weight: Weight of the seal/protector from vendor catalog.
Housing Diameter: Outer diameter of housing from vendor catalog.
Shaft OD: Outer diameter of standard shaft from vendor catalog.
Abrasion Resistant Shaft OD: Outer diameter of abrasion resistant
shaft from vendor catalog.
Std Shaft Power Limit:
Standard shaft power limit from vendor
catalog.
AR Shaft Power Limit: Abrasion resistant shaft power limit from
vendor catalog.
Custom seal/protectors are entered in one or more elements to simulate
the change in stiffness of the component along its length. Elements are
sub-sections of a complete component that capture changes in outer or
inner diameter of the component. A new element should be created for
any significant change in outer or inner diameter of the component that
will result in a change in stiffness. Contact C-FER for more detailed
information on obtaining and entering this information.
Component
Component
Component
Component
Component
Component
Component

Element
Element
Element
Element
Element
Element
Element

Length: Length of the element.

Outer Diameter: Outer diameter of the element.
Inner Diameter: Inner diameter of the element.
Weight: Weight of the element.
EI: Bending stiffness of the element.
AE: Axial stiffness of the element.
GJ: Torsional stiffness of component.

Component Maximum Curvature:

Maximum curvature that the
element can withstand.
Component Maximum Stress: Maximum stress that the element can
withstand.
5. To remove a seal/protector from a database, select it by highlighting its
name, right-click the mouse and select "Delete Model".
Once you have finished, click OK to close the Custom Equipment input
window. All of the new custom seal/protector databases and their
corresponding seal/protector models will now be available for selection and
use in the ESPBend equipment database.

You are here: Auxillary Analysis > ESPBend Custom Tubing

ESPBend Custom Tubing

Note: The ESPBend tool is currently in Beta testing. Please contact CFER if you would like to use the ESPBend module in PC-PUMP.
You can create new tubing models that can be added to your own custom
databases. The tubing can subsequently be selected and used in the same
manner as any of the tubing included in the ESPBend equipment database.
You can add custom tubing by opening the
"Custom Equipment".

Tools

menu option and selecting

Custom Equipment Window

Specifying Custom Tubing Information

1. On the left-side of the Custom Equipment window, you can select a custom
tubing database. Each database may contain one or more custom tubing
models. Once a database is selected, the names of these models will
appear under it. Highlighting a particular tubing model will display the
specifications of the selected model. If an existing tubing model is selected
to be edited, proceed to Step 4.
2. To create a new custom tubing database, select "tubing" and click the Add
File button. This will bring up a window into which you must enter a Tubing
Description and a File Name. Although a file name is automatically
created, you can modify it within the lower edit box. When finished, click
the OK button.

New File: Custom Tubing Window

3. Once a file has been created, new custom tubing models can be created by
right-clicking on the file name and selecting the "Add Model" option.
Alternatively, you can duplicate an exiting model by selecting a tubing
model, right-clicking, and selecting "Duplicate Model". When you have
added a new model to the file, you can enter or update the model
specifications located on the right-side of the screen.

Custom Tubing Model Input Window

4. The following specifications are required for custom tubing:

Part Number: Unique part number.
Tubing OD: Outer diameter of tubing body.
Tubing Grade: Grade of tubing.
Tubing Type: Tubing connection type (Non-Upset, Upset, Integral
Joint).
Tubing Weight: Weight of the tubing per unit length.
Tubing ID: Inner diameter of the tubing body.
Tubing Drift ID: Drift diameter of the tubing.
Connection OD: Outer diameter of the tubing connection.
Upset OD: Outer diameter of the tubing upset (if applicable).
Collapse Pressure: Tubing collapse pressure.
Internal Yield Pressure: Internal yield pressure of the tubing.
Joint Yield Load: Maximum allowable yield load on the tubing joint.
Number of Nodes: Number of nodes is the number of elements (see
below) plus 1.
Custom tubing is entered in one or more elements to simulate the change
in stiffness of the component along its length. Elements are sub-sections of
a complete component that capture changes in outer or inner diameter of
the component. A new element should be created for any significant
change in outer or inner diameter of the component that will result in a
change in stiffness. Contact C-FER for more detailed information on
obtaining and entering this information.
Component Element Length: Length of the element.
Component Element Outer Diameter: Outer diameter of the element.
Component Element Inner Diameter: Inner diameter of the element.
Component Element Weight: Weight of the element.
Component Element EI: Bending stiffness of the element.
Component Element AE: Axial stiffness of the element.
Component Element GJ: Torsional stiffness of component.
Component Maximum Curvature:
Maximum curvature that the
element can withstand.

Component Maximum Stress: Maximum stress that the element can

withstand.
5. To remove tubing from a database, select it by highlighting its name, rightclick the mouse and select "Delete Model".
Once you have finished, click OK to close the Custom Equipment input
window. All of the new custom tubing databases and their corresponding
tubing models will now be available for selection and use in the ESPBend
equipment database.

You are here: Auxillary Analysis > Session 1: Basic ESP-BEND Analysis

Session 1: Basic ESP-BEND Analysis

Note: The ESPBend tool is currently in Beta testing. Please contact CFER if you would like to use the ESPBend module in PC-PUMP.
Note: The ESPBend calculation is conducted independently of the main
calculation loop and will only function if you have already completed
the primary analysis and have entered a wellbore profile.
Note: The samples in this Help File are based on PCPUMP v3.3.7. If you are
using a later version of the program, or an updated database, some of the
results you get may not be the same. Also, some of the equipment selected in
this Help File may no longer be available in the database. If this is the case,
select the closest match available.
As an introduction to ESPBend, this session describes the process which might
be followed to assess the bending in an ESP system. It illustrates how to enter
a wellbore profile, select ESP equipment, perform standard calculations and
review output graphs.

Scenario:
An ESP system is being run into a horizontal well. The wellbore has a high
dogleg severity (up to 7.7/100ft), and there is concern that bending and
stress on the ESP system will exceed acceptable limits.

Objective:
Determine if the ESP system can be run into the well with the existing
configuration.

Data:
Wellbore Geometry
Well Type: Horizontal
- target vertical depth = 450 m (5 m)
- lateral offset = 100 m (Well #2 West, Well #3 East)
- departure before target depth = 300 m (North)
- horizontal section = 500 m
ESP System Configuration (ESPBend Window):

Casing: 177.8 mm x 34.23 kg/m (7" x 32 lbs/ft)

Tubing: 73.0 mm x 9.67 kg/m, J-55, Upset (2-7/8" x 6.5 lbs/ft)
Bolt-On Head: ESP Inc. 400 Series Bolt-On Head (Part # 93982-1)
Pump: ESP Inc. 400 Series, TD-1750, 3, Standard, Floating Impeller (Part
# 93982-7)
Bolt-On Intake: ESP Inc. 400 Series, Standard (Part # 93585-8)
Seal/Protector: ESP Inc. 400 Series, TR4-SBG Single Bag PFSB, Standard
(Part # 110827-5)
Motor: ESP Inc. 400 Series STD, Upper Tandem, 10HP (Part # 110752)

Procedure:
In this session, you will:
enter a wellbore geometry with the well design window;
enter ESP equipment into the ESP-BEND tab; and
determine if bending and stress on the ESP is within acceptable limits
when running the pump into the horizontal.
The first step of this assessment is the creation of a suitable directional well
profile. Click the Wellbore Geometry tab to move into the well geometry
portion of the program. Within this module, you can input, process and
display survey data and charts for either existing or proposed directional well
geometries. Because you are designing a new well and there is no directional
survey available, the well design mode must be used to create a directional
proposal. Bring up the Well Design window by clicking the Well Design button.
Within Well Design window, you can create a directional wellbore survey by
entering a series of lengths, build rates and plan curvatures into the left-side
of the table. Note that positive build rates correspond to a wellbore that is
increasing angle while positive plan curvature corresponds to a wellbore that is
moving left to right in plan view. When you click the OK button, each
segment's measured depth, hole angle, azimuth, dogleg severity, vertical
depth, horizontal distance, latitude and departure will be computed and
displayed. You can also examine the profiles graphically by selecting the Chart
tab at the top of the window. For practice, try constructing some different well
profiles. Right-click to insert rows, delete a row or delete all rows.
For this particular example, you must construct a well profile that will reach
horizontal (i.e. 90) at a total vertical depth (TVD) of 450 m and an East-West
departure of 100 m. In addition, the target TVD must be established by 300 m

North of surface and hold at this depth for 500 m. Although this can be
achieved using numerous different well shapes, for consistency create a well
profile with the following segments:
Segment Length Build Rate

Plan Curvature

64.6 m

0 /30m

0 /30m

95 m

3 /30m

0 /30m

210 m

5 /30m

6 /30m

210 m

5 /30m

-6 /30m

105 m

3 /30m

0 /30m

500 m

0 /30m

0 /30m

Once you have entered the data into the spreadsheet, the updated screen will
appear as shown below.

The proposed wellbore will have a final measured depth of 1184.6 mKB, hole
angle of 90, vertical depth of 450 m and departure of 99.9 m. Select the
Chart tab to view the profile graphically. As you will use this profile for the
analysis, click the OK button to exit Well Design window.
Upon exiting the Well Design window, a directional proposal spaced at 10 m
will be generated based on the specified inputs. The proposal survey data will
be displayed within the large table in the Table tab of the Wellbore Geometry
window. If necessary, use the horizontal and vertical scroll bars to move about
the table in order to access the full range of data.
To view the directional well data in graphical form, select the Charts tab to
bring up the window shown below.

Use the Chart drop-down list to switch between the different chart types that
are available.
In addition to the detailed information displayed in the survey table, PCPUMP
also calculates several other parameters related to wellbore geometry. This
summary information is displayed in the Summary tab. The Summary tab for
the proposed well should appear as shown below.

Now that you have generated an appropriate wellbore profile, a PC-PUMP case
must be successfully calculated to access to the ESP-BEND tab. Here you will
select 177.8 mm x 34.23 kg/m (7" x 32 lbs/ft) casing, 73.0 mm x 9.67 kg/m,
J-55 Upset (2-7/8" x 6.5 lbs/ft) tubing, the ESP Inc. 400 Series Bolt-On Head
(Part # 93982-1), and the ESP Inc. 400 Series, Standard (Part # 93585-8) by
clicking on the drop-down list next to each item and selecting the desired
equipment.
Next, you will select the ESP Inc. 400 Series, TD-1750, 3, Standard, Floating
Impeller (Part # 93982-7) pump, ESP Inc. 400 Series, TR4-SBG Single Bag
PFSB, Standard (Part # 110827-5) seal and ESP Inc. 400 Series STD, Upper
Tandem, 10HP (Part # 110752) motor by clicking on the first drop-down list in
the selection area corresponding to the equipment you are entering. When
finished entering equipment, the ESP-BEND tab should appear as follows.

Click the Calculate button in the bottom left corner to start the analysis. The
ESP-Bend Results window should appear. Begin by changing the Survey
Interval to the depth of the most severe dogleg (569.59-579.59 mKB) to
review the results at this depth. The output windows are shown below.
The "Deflected Shape" graph shows the casing boundaries, casing center line
and ESP start and end coordinates in the plane of curvature. Node 28 [Outer],
Node 29 [Outer], Node 48 [Outer] and Node 89 [Outer] represent points of
contact between the ESP system and the casing on the outer radius of the
curvature. We can see that the ESP system is contacting the low side of the
casing when comparing the ESP Final Coordinates to the casing center.

The "Shape Relative to Casing in plane of curvature" graph shows a visual

representation of the casing ID, the tubing/ESP OD and the tubing/ESP axis.
We see there is bending in the plane of curvature at this depth, with four
points of contact along the ESP system/tubing. The blue points represent the

points of contact between the ESP/tubing system and the casing.

The "Shape perpendicular to plane of curvature" graph shows a visual

representation of the casing ID, the tubing/ESP OD and the tubing/ESP axis.
We see there is little bending perpendicular to the plane of curvature at this
depth, since there is no change in azimuth at 569.59-579.59 mKB.

The "Shear vs. Length" graph shows the shear force along the length of the
ESP system. The shear force is highest at Node 274 at around 1485 N. The
shear force is used to calculate the stress in the ESP components.

The "Moment vs. Length" graph shows the bending moment along the length
of the ESP system. The bending force is highest at about 12.3 m at around
1150 Nm.

To check if the stress is below acceptable limits, review the "Stress vs. Length"
graph. This graph shows the maximum element stress and the stress limit
along the length of the pump. The results show that the current configuration
is well below the acceptable limit along the entire length of the pump.

To check if the curvature is below acceptable limits, review the "Curvature vs.
Length" graph. This graph shows the element curvature and the curvature
limit along the length of the pump. The results show that the current
configuration is above the acceptable limit at about 12.1 m along the length of
the ESP system/tubing at around 21/30m.

Finally, the "Stiffness and Diameter graph" shows the bending stiffness of the
ESP system and the outer diameter along the length of the pump.

Note that the results of the calculation should be reviewed along the entire
length of the wellbore to ensure that stress and curvature do not exceed
acceptable limits at any depth.

This first sample session was intended to provide an introduction to ESPBend

and to demonstrate the use of the software in its most basic mode. In a
subsequent sample session, you will be introduced to ESPBend's custom
equipment options and wellbore geometry input.

You are here: Auxillary Analysis > Session 2: ESP-BEND Analysis with Custom Equipment

Session 2: ESP-BEND Analysis with Custom

Equipment
Note: The ESPBend tool is currently in Beta testing. Please contact CFER if you would like to use the ESPBend module in PC-PUMP.
Note: The ESPBend calculation is conducted independently of the main
calculation loop and will only function if you have already completed
the primary analysis and have entered a wellbore profile.
Note: The samples in this Help File are based on PCPUMP v3.3.7. If you are
using a later version of the program, or an updated database, some of the
results you get may not be the same. Also, some of the equipment selected in
this Help File may no longer be available in the database. If this is the case,
select the closest match available.
As an introduction to ESPBend, this session describes the process which might
be followed to assess the bending in an ESP system. It illustrates how to enter
a wellbore profile, select ESP equipment, perform standard calculations and
review output graphs.

Scenario:
An ESP system is being run into a deviated well. The wellbore has a moderate
dogleg severity (up to 4.6/30ft), and there is concern that bending and stress
on the ESP system will exceed acceptable limits.

Objective:
Determine if the ESP system can be run into the well with the existing
configuration.

Data:
Wellbore Geometry
Well Type: Directional
ESP System Configuration (ESPBend Window):
Casing: 177.8 mm x 34.23 kg/m (7" x 32 lbs/ft)
Tubing: 73.0 mm x 9.67 kg/m, J-55, Upset (2-7/8" x 6.5 lbs/ft)

Bolt-On Head: ESP Inc. 400 Series Bolt-On Head (Part # 132160)
Bolt-On Intake: ESP Inc. 400 Series,Abrasion Resistant (Part # 110266)
Seal/Protector: ESP Inc. 400 Series, TR4-SBG Labyrinth Hi-Load W/HSS,
Standard (Part # 120618)
Motors: Two ESP Inc. 400 Series STD, Upper Tandem, 10HP (Part #
110752)
Custom Pump Information:
Model 1200 Pump
400 Series
Standard (Non-Abrasion Resistant)
Part Number: 123456
Housing Number: 4
Length: 1.92 m
Weight: 60.6 kg
Number of Nodes: 10
Number of Stages: 73
Floating Impeller
Pump OD: 101.6 mm
Pump Housing OD: 101.6 mm
Minimum Casing ID: 139.7 mm
Shaft Diameter: 17.46 mm
Standard Shaft Limit: 104.6 hp
High Strength Shaft Limit: 167.6 hp
Housing Pressure Limit: 34 MPa
Rotation Direction: Counter-clockwise
Maximum Number of Stages with Standard Shaft: 486
Maximum Number of Stages with Standard Thrust Bearing: 297
Maximum Number of Stages with High Load Thrust Bearing: 1648
Maximum Number of Stages with High Strength Shaft: 778

Procedure:
In this session, you will select optimal:
Load a saved wellbore profile;
enter a custom pump into ESPBend; and

perform an ESPBend analysis.

The first step in this assessment is to input the directional survey data for the
well in the Wellbore Geometry tab. For an existing directional well, normally
you must manually enter the directional survey information directly into the
table in the Table tab. Starting at surface, the measured depth, hole angle
and azimuth values are entered for each survey station. As the data is
entered, the calculated parameters are automatically updated.
If the directional survey data has been previously entered or is available in a
format which can be read, it can be imported directly into the wellbore
geometry table. The survey file for the well being considered in this sample
session was included with the files shipped with the program. To import it,
click the Import button, select the file type '.wbr' and select the "samps3.wbr"
file from your default Wellbore file directory. The window will be updated with
the survey data and appear as shown below.

Using the Summary tab, you can establish that the well has a total measured
depth of 703.0 mKB, a total vertical depth of 623.0 Vm and a final hole angle
of 34.3.
Select the Charts tab to view the directional survey data graphically. By
selecting the Dogleg Severity chart, you can see the wellbore curvature
profile. Note that the dogleg severity is highest in the upper portion of the
well and tends to decline with depth. The maximum curvature of 4.5/30 m
occurs at a measured depth of about 93 mKB.

Specifying Custom Pump Information

Since the ESP being run into the well is not currently in the ESPBend
database, you must enter a custom ESP Pump by clicking the Tools menu
option and selecting "Custom Equipment".
1. On the left-side of the Custom Equipment window, you can select a custom
pump database. Each database may contain one or more custom pump
models. Once a database is selected, the names of these models will
appear under it.
Highlighting a particular pump will display the
specifications of the selected model.
2. To create a new custom pump database, select "Pump" and click the Add File
button. This will bring up a window into which you must enter a Pump

Description and a File Name. Although a file name is automatically

created, you can modify it within the lower edit box. When finished, click
the OK button.

New File: Custom Pump Window

3. Once a file has been created, new custom pump models can be created by
right-clicking on the file name and selecting the "Add Model" option. When
you have added a new model to the file, you can enter or update the
model specifications located on the right-side of the screen. Start by
entering the following information about your custom pump:
Model 1200 Pump
400 Series
Standard (Non-Abrasion Resistant)
Part Number: 123456
Housing Number: 4
Length: 1.92m
Weight: 60.6 kg
Number of Nodes: 10
Number of Stages: 73
Floating Impeller
Pump OD: 101.6 mm
Pump Housing OD: 101.6 mm
Minimum Casing ID: 139.7 mm
Shaft Diameter: 17.46 mm
Standard Shaft Limit: 104.6 hp
High Strength Shaft Limit: 167.6 hp
Housing Pressure Limit: 34 MPa
Rotation Direction: Counter-clockwise
Maximum Number of Stages with Standard Shaft: 486
Maximum Number of Stages with Standard Thrust Bearing: 297
Maximum Number of Stages with High Load Thrust Bearing: 1648
Maximum Number of Stages with High Strength Shaft: 778

Custom Pump Model Input Window

4. Custom pumps are entered in one or more elements to simulate the

change in stiffness of the component along its length. An element should
be entered to capture changes in outer or inner diameter of the
component. Contact C-FER for more detailed information on how to obtain
and enter this information. For this sample session, enter the information
below into the Component Elements tab:

AE (Pa-m2)

GJ (Pam4)

Maxim
Curvat
(/30

916816

1021891655

684556

14.8

0.460

575979

652176493

430064

14.8

71.12

0.53

822137

855244726

613862

14.8

101.6

71.12

0.67

822137

855244726

613862

14.8

0.043

101.6

71.12

1.78

822137

855244726

613862

14.8

1.680

101.6

88.9

51.26

447711

393035286

334291

14.8

0.029

101.6

69.85

1.21

840200

884329283

627350

14.8

0.025

101.6

58.42

1.32

963636

1122508703

719515

14.8

0.053

66.8

46.99

0.99

152077

365143785

113551

14.8

0.013

101.6

46.99

0.79

1032398

1318240278

770857

14.8

Length
(m)

OD
(mm)

ID
(mm)

Weight
kg)

EI (Pam4)

0.033

101.6

63.5

1.60

0.014

95.25

71.12

0.013

101.6

0.016

Once you have finished, click OK to close the Custom Equipment input
window. All of the new custom pump databases and their corresponding pump
models will now be available for selection and use in the ESPBend equipment
database.

Calculating an ESPBend Case With the Custom Pump

Now that you have generated an appropriate wellbore profile and created your
custom pump, a PC-PUMP case must be successfully calculated to access to the
ESP-BEND tab. Here you will select 177.8 mm x 34.23 kg/m (7" x 32 lbs/ft)

casing, 73.0 mm x 9.67 kg/m, J-55 Upset (2-7/8" x 6.5 lbs/ft) tubing, an ESP
Inc. 400 Series Bolt-On Head (Part # 132160), and a ESP Inc. 400 Series,
Abrasion Resistant (Part # 110266) bolt-on intake by clicking on the dropdown list next to each item and selecting the desired equipment.
Next, you will select the custom 400 series pump, ESP Inc. 400 Series, TR4SBG Labyrinth Hi-Load W/HSS, Standard (Part # 120618) seal and two ESP
Inc. 400 Series STD, Upper Tandem, 10HP (Part # 110752) motors by clicking
on the first drop-down list in the selection area corresponding to the
equipment you are entering. When finished entering equipment, the ESPBEND tab should appear as follows.

Click the Calculate button in the bottom left corner to start the analysis. The
ESP-Bend Results window should appear. Begin by changing the Survey
Interval to the depth of the most severe dogleg (93-102 mKB) to review the
results at this depth. The output windows are shown below.
The "Deflected Shape" graph shows the casing boundaries, casing center line
and ESP start and end coordinates in the plane of curvature. The ESP and
tubing are contacting the casing at two points (Node 48 [Outer] and Node 103
[Outer]).

To check if the stress is below acceptable limits, review the "Stress vs. Length"
graph. This graph shows the maximum element stress and the stress limit
along the length of the pump. The results show that the current configuration
is well below the acceptable limit along the entire length of the pump.

To check if the curvature is below acceptable limits, review the "Curvature vs.
Length" graph. This graph shows the element curvature and the curvature
limit along the length of the pump. The results show that the current
configuration exceeds the acceptable limit at about 13 m along the length of
the ESP system/tubing at around 18/30m. Changes to the ESP components
and materials should be considered in order to reduce the curvature of the ESP
system.

Note that the results of the calculation should be reviewed along the entire
length of the wellbore to ensure that stress and curvature do not exceed

acceptable limits at any depth.

This sample session was intended to provide an introduction to custom
equipment in ESPBend and to demonstrate the use of the software. For
further assistance with ESPBend please contact C-FER.

You are here: Appendices > Appendix A: References

Appendix A: References

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46.

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Network HASP Installation

If you are using a network HASP, you will need to install the HASP run-time (if
PC-PUMP is not installed on the licence server).

Server Installation Instructions

1. Plug the HASP key into the server.
2. Install the HASP run-time by copying the Support folder from a computer
where PC PUMP is installed (C:\Program Files\C-FER Technologies\PCPump\Support) locally to the licence server. Run haspdinst.bat from the
copied Support folder.
NOTE: This step is only necessary if PC-PUMP is not installed on the
licence server.
3. Launch the Sentinel HASP Manager Admin Control Center by opening an
instance of Internet Explorer (or another internet browser) and typing
http://localhost:1947 into the address box.

4. Click on the "Sentinel Keys" link to verify the HASP key is detected. If the
HASP has been detected, it will be listed in the table as seen in the
screenshot below. If the HASP is visible in the HASP Keys table, it has been
detected and is ready to use.

Client Installation Instructions

1. Install PCPUMP on the client computer by following the instructions
obtained from CFER. Part of the installation process is installation of the
HASP Drivers. This must be done whether a network or stand-alone HASP
is to be used. You must have Administrator access privileges to do this.
2. If the network HASP is on a different sub-net on your network from the
computer you are using to run PCPUMP, PCPUMP may not be able to locate

the HASP without special instructions. In order to run PCPUMP with a

network key in this case, access the Sentinel HASP Manager Admin Control
Center by opening an instance of Internet Explorer (or another internet
browser) and typing http://localhost:1947.
Next, click on "Configuration" in the menu on the left to begin configuring
your Sentinel License Manager. Next, click the "Access to Remote License
Managers" tab to begin configuring your network settings:

Allow
Access to
Remote
Licenses

Enables your machine to search for remote Sentinel

License Managers on the local network. When you allow
access to remote licences, you must either select
"Broadcast Search for Remote Licenses", specify IP
addresses in the "Specify Search Parameters" area, or both.
This option should be checked.

Broadcast
Search for
Remote
Licenses

Enables your machine to search for remote Sentinel

License Managers on the local network via broadcasts. This
option should be checked.

Aggressive
Search for
Remote
Licenses

Aggressive searching reduces the update frequency of

remote Sentinel information and enables your machine to
connect to remote Sentinel License Managers, even though
they cannot be detected using UDP datagram search
methods. Note that this option may enable firewalls to be
transversed. This option does not need to be checked.
Defines the specific machines that may be searched by this
machine for remote Sentinel License Managers.

Specify
Search
Parameters

Specify data as IP addresses (for example, 10.1.1.17),

Broadcast addresses (for example, 10.1.1.255), or
machine names (for example, hklm001.ecomp.com).
When using the IPv6 protocol, use the IPv6 address
format. For example, type FF02::1 to access all remote
Sentinel License Managers that are part of the default
local group defined in the IPv6 subnet.
Each entry must be on a separate line. This option may
be necessary to locate licences on servers.

For further information, click the "Help" button in the bottom right of the
Sentinel HASP Manager Admin Control Center at any time for context
sensitive help.
If you have any questions about PCPUMP, the upgrade, or how to install it,
please contact CFER at (780)450-3300 or at pcpump@cfertech.com.

Notes for Former PC-PUMP Hardlock Users

For PC-PUMP users who are familiar with the network Hardlock, the biggest
difference between the network Hardlock and HASP is the program used to
administer the network lock. The Aladdin Monitor program is only compatible
with Hardlocks and some of the very first HASP-related products.
With the newer HASP technologies, all administration of the lock is done
through the Sentinel HASP Manager Admin Control Center. The "Control
Center" has online Help that explains all the different options available to the
server administrator.

Related Topics
System Requirements
Licence Protection
Updating Hardlock Feature
Codes
Installation
Using PCPUMP